fruitcore robotics HORST600 Assembly Instructions Manual

Robot System HORST600
Assembly Instructions
For installation, operating, and maintenance personnel
Always keep with the product!
Version 3.1 / 09.02.2022
1
Copyright
© by fruitcore robotics GmbH
fruitcore robotics GmbH claims copyright protection for these documents.
Original language of the documentation: German
This documentation must not be altered, expanded, reproduced, or passed on to third parties without the
previous written consent of fruitcore robotics GmbH.
fruitcore robotics GmbH
Macairestr. 3
78467 Konstanz, Germany
Telephone: (+)49 (0)7531 / 945 99-20
Email:
[email protected]
Website:
www.fruitcore-robotics.com
Date of issue: February 2022
Subject to design and machine alterations
2
3
Contents
1
Introduction ................................................................................................................. 1
1.1
Principle ........................................................................................................................................... 1
1.2
General Information ...................................................................................................................... 1
1.3
Operating Responsibility and Liability ........................................................................................ 1
1.3.1
2
Legal Disclaimer ............................................................................................................ 2
1.4
Warranty .......................................................................................................................................... 2
1.5
Organizational Measures ............................................................................................................. 2
1.6
Applied Standards and Regulations ........................................................................................... 2
1.7
Signs, symbols ............................................................................................................................... 3
1.8
Marking of the Safety and Warning Signs ................................................................................ 3
Safety............................................................................................................................ 5
2.1
General Safety Information .......................................................................................................... 5
2.2
Proper Use ...................................................................................................................................... 5
2.3
Improper Use .................................................................................................................................. 6
2.3.1
2.4
Operator’s Duties ........................................................................................................................... 7
2.4.1
2.4.2
2.4.3
2.5
Foreseeable Misuse...................................................................................................... 6
EU Declaration of Conformity and Declaration of Incorporation ......................... 7
Risk Assessment by the Operator.............................................................................. 7
Operations Manager ..................................................................................................... 8
Operating Personnel...................................................................................................................... 9
2.5.1
2.5.2
Obligation of the Operating Personnel ...................................................................... 9
Training of the Operating Personnel.......................................................................... 9
2.6
Working Area, Danger Zone, and Safe Area .............................................................................. 9
2.7
Safety Functions .......................................................................................................................... 10
2.8
Safety Information for Assembly and Commissioning ........................................................ 11
2.9
Safety Information on Operation .............................................................................................. 12
2.9.1
2.9.2
Emergency Situations ................................................................................................ 12
Emergency Operation – Moving the Robot without Drive Power ...................... 13
2.10 Safety Information for Fault Rectification, Cleaning, and Maintenance Work ................ 15
2.11 Residual Danger .......................................................................................................................... 15
3
Transport ................................................................................................................... 18
4
Description of the Robot System .......................................................................... 19
4.1
Scope of Delivery ......................................................................................................................... 19
4.2
Modules ......................................................................................................................................... 20
4.2.1
4.2.2
4.2.3
4
Robot ............................................................................................................................. 20
horstPANEL (operating panel) .................................................................................. 21
horstCONTROL (switch cabinet) .............................................................................. 23
4.3
Protection Devices ....................................................................................................................... 24
4.3.1
4.3.2
4.4
5
Add-on Parts & Tools (Option)................................................................................................... 24
Assembly ................................................................................................................... 25
5.1
Working Area of the Robot ......................................................................................................... 25
5.2
Assembly of the Robot ............................................................................................................... 26
5.2.1
5.2.2
5.2.3
5.3
5.4
Electrical Installation................................................................................................ 30
6.1
Electrical System Warning Notes ............................................................................................. 30
6.2
Robot Connection ........................................................................................................................ 31
6.3
Power Connection ....................................................................................................................... 32
6.4
horstCONTROL I/O ...................................................................................................................... 33
Overview of All Interfaces .......................................................................................... 34
Safety-critical Inputs/Outputs ................................................................................... 35
Test Signals A/B .......................................................................................................... 39
General Digital Inputs ................................................................................................. 40
General Digital Outputs .............................................................................................. 41
+24 V Power Supply .................................................................................................... 42
Common Features of All Digital Interfaces ............................................................ 43
Wiring Examples of Safety-critical Inputs/Outputs............................................... 45
Wiring Examples of Digital Inputs/Outputs ............................................................ 48
6.5
Tool I/O .......................................................................................................................................... 49
6.6
Computer Interfaces ................................................................................................................... 51
6.6.1
6.6.2
6.6.3
8
Pneumatic Connection of Add-on Parts ................................................................. 29
Setting Up horstCONTROL ......................................................................................................... 29
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9
7
Mounting Surface ........................................................................................................ 26
Assembling the Robot ................................................................................................ 27
Restricting the Movement Space ............................................................................. 27
Assembling Add-on Parts ........................................................................................................... 28
5.3.1
6
Enabling switch............................................................................................................ 24
Emergency Stop Button ............................................................................................. 24
PROFINET (optional)................................................................................................... 51
Ethernet ......................................................................................................................... 51
USB................................................................................................................................. 51
Commissioning......................................................................................................... 52
7.1
Switching on the Robot System ................................................................................................ 53
7.2
Initializing the Robot .................................................................................................................... 54
Operation ................................................................................................................... 57
8.1
Behavior in an Emergency .......................................................................................................... 57
8.2
Operating Modes ......................................................................................................................... 58
8.2.1
8.2.2
Teaching mode ............................................................................................................ 59
Automatic Mode .......................................................................................................... 61
5
8.3
9
Shutdown after End of Operation ............................................................................................. 63
Fault Rectification .................................................................................................... 65
10 Cleaning and Maintenance ..................................................................................... 66
10.1 Cleaning........................................................................................................................................ 66
10.2 Maintenance and Repair ........................................................................................................... 67
11 Storage ....................................................................................................................... 68
12 Disassembly and Disposal ..................................................................................... 69
12.1 Disassembly ................................................................................................................................ 69
12.2 Disposal ........................................................................................................................................ 69
13 Annex .......................................................................................................................... 70
13.1 Technical Data ............................................................................................................................ 70
13.2 Stopping Distances and Stopping Times .............................................................................. 73
13.3 Optional Accessories ................................................................................................................. 75
13.4 Spare Parts .................................................................................................................................. 77
13.5 Type Plates .................................................................................................................................. 78
13.6 Overview of Connectors ............................................................................................................ 79
13.7 Terminal Assignment ................................................................................................................ 80
13.8 Functional Wiring Diagrams of the Electrical Interfaces .................................................... 82
13.8.1
13.8.2
horstCONTROL I/O ..................................................................................................... 82
Tool I/O 83
14 Glossary ..................................................................................................................... 84
6
List of Tables
Table 6-1: Mains connection characteristic values ......................................................................................................... 32
Table 6-3: Configurable functions for safe inputs ........................................................................................................... 38
Table 6-4: Configurable functions for safe outputs ......................................................................................................... 39
Table 6-5: Test signal characteristic values ...................................................................................................................... 39
Table 6-6: Configurable functions for general digital inputs .......................................................................................... 40
Table 6-7: Configurable functions for general digital outputs ....................................................................................... 41
Table 6-8: Characteristic values of the +24 V power supply .......................................................................................... 42
Table 6-9: Characteristic values of digital I/O horstIO .................................................................................................... 43
Table 6-10: Characteristic values of tool inputs/outputs ............................................................................................... 50
Table 12-1: Materials used ................................................................................................................................................... 69
Table 13-1: Stopping distances and times with horstFX performance ....................................................................... 73
Table 13-2: Optional accessories ........................................................................................................................................ 75
Table 13-3: Spare Parts......................................................................................................................................................... 77
Table 13-4 Digital I/O horstCONTROL connectors .......................................................................................................... 79
Table 13-5: Terminal assignment of digital I/O horstCONTROL ................................................................................... 81
7
List of abbreviations
µs
HI
HORST
I/O
kV
kΩ
LO
mA
ms
mΩ
OSSD
TCP
Ω
8
Microseconds
High, Logical 1
Highly Optimized Robotic Systems Technology
Input/Output
Kilovolt
Kilo ohm
Low, Logical 0
Milliampere
milliseconds
Milli ohm
Output Switching Signal Device
Tool Center Point
Ohm
1 Principle
1
Introduction
1.1
Principle
The Assembly Instructions contain important information on how to operate the robot system in a safe,
proper, and economically efficient way. Adherence to these Assembly Instructions helps to avoid hazards,
reduce repair costs and downtime, and to increase the reliability and service life of the robot system.
The operator is obligated to add instructions arising from existing national or company regulations on
accident prevention and environmental protection to the Assembly Instructions.
The Assembly Instructions must always be available at the site of operation of the robot system.
Read the Assembly Instructions carefully and completely before commissioning the robot system.
Treat the Assembly Instructions with care. Illegible or missing Assembly Instructions must be
replaced immediately.
For the efficient and safe control, programming and operation of the robot, please also read the
detailed description of the user software in the Software horstFX user manual, which is always
accessible on www.horstcosmos.com.
1.2
General Information
The Assembly Instructions include a detailed description of the robot system and guidelines for transport
and installation as well as comprehensive instructions for operating the robot system, tips for fault rectification, and information on maintenance.
The robot system delivered may include options that deviate from the text and images shown
in these Assembly Instructions. This is due to the individual adaptation and further development of the robot system on the basis of the requests and orders of the individual customers.
These deviations do not constitute a basis for claims of any kind.
The robot system must be used only for the permissible purposes listed in the Assembly Instructions.
The manufacturer assumes no liability for the improper or unauthorized use of the robot system, operating errors, user errors or improper or insufficient maintenance.
Section 2 Safety of the Assembly Instructions contains instructions and associated information on the
safe use of the robot system. The instructions specified in this section must always be observed.
1.3
Operating Responsibility and Liability
Operating responsibility lies with the operator of the robot system. The operations manager and all operators are obligated to act according to these Assembly Instructions.
The safety and accident prevention regulations of the following institutions must be observed:
−
The country’s laws
−
The trade associations
−
The responsible commercial liability insurance company.
The operations manager, the operating personnel, or – if the former cannot be held responsible due to a
lack of training or basic knowledge – their supervisory staff will be charged with accidents resulting from
the failure to observe these Assembly Instructions, safety and accident prevention regulations, or a lack
of care. Therefore, please take due care and caution.
1
1 Warranty
1.3.1
Legal Disclaimer
We expressly stipulate that the manufacturer shall not be liable for damage caused by incorrect or negligent operation or maintenance, or improper use. This also applies to modifications and additions to as
well as conversions of the robot system that may impair its safety. The manufacturer’s liability shall expire
in these cases.
1.4
Warranty
Unless otherwise agreed upon in the purchase contract, we will grant the legally prescribed warranty period for the robot system and spare parts, starting on the day of delivery.
The warranty provisions specified in the general terms and conditions of fruitcore robotics GmbH or the
individual purchase contract apply in addition.
1.5
Organizational Measures
The responsibilities when operating the robot system must be clearly defined and observed to ensure that
no unclear responsibilities arise with regard to the aspect of safety (e.g. “Who switches off the robot?”,
“Who secures the robot against unauthorized use?”, “Who controls the safety components?”).
An operations manager must be appointed by the operator. The operations manager is obligated to allow
the operating personnel time for work and safety instruction on the basis of the these Assembly Instructions. Malfunctions must be reported to the operations manager immediately.
In addition, the operator must observe and provide instruction on generally applicable legal and other
binding regulations on accident prevention and environmental protection.
1.6
Applied Standards and Regulations
The following standards and regulations were applied during the development of the robot system.
2
−
EU Directive 2006/42/EC
Machinery Directive
−
DIN EN ISO 10218-1
Robots and robotic devices – Safety requirements – Part 1: Robots
−
DIN EN ISO 12100
Safety of Machinery – General principles of design – Risk assessment and risk reduction
−
DIN EN ISO 13849-1
Safety of Machinery – Safety-related parts of control systems –
Part 1: General principles of design
−
DIN EN ISO 13849-2
Safety of Machinery – Safety-related parts of control systems – Part 2: Validation
−
DIN EN ISO 13850
Safety of Machinery – Emergency stop principles of design
−
DIN EN ISO 14118
Safety of Machinery – Prevention of unexpected start-up
−
DIN EN 60204-1/A1
Safety of Machinery – Electrical equipment of machines – Part 1: General requirements
−
DIN EN 60529
Degrees of protection provided by enclosures
−
ISO 9409-1
Industrial robots– Mechanical interfaces – Part 1: Plates
1 Signs, symbols
1.7
Signs, symbols
The following symbols are used in the Assembly Instructions:
Lists
−
Simple lists are marked with “–”.
Instructions for action
All instructions for action for a procedure are listed in chronological order.
 Instructions are marked with “”.  Intermediate results and end results of the action are
marked with “⇒”.
Note
This symbol stands for information that allows a more effective and economically efficient use of
the robot system.
1.8
Marking of the Safety and Warning Signs
The following safety signs mark all actions that present a danger to life and limb of the operator or others
around the operator.
Make sure to observe these signs and exercise particular caution in these cases. Also pass on the safety
signs to other users.
DANGER!
The sign with the addition DANGER refers to an immediate danger.
The danger will lead to serious injury or death of persons.
 The description of the danger is followed by instructions for action that serve to avoid or
remove the danger.
WARNING!
The sign with the addition WARNING refers to possible danger.
The danger can lead to serious injury or death of a person.
 The description of the danger is followed by instructions for action that serve to avoid or
remove the danger.
CAUTION!
The sign with the addition CAUTION refers to a potentially hazardous situation.
The danger can lead to injury of persons.
 The description of the danger is followed by instructions for action that serve to avoid or
remove the danger.
The safety signs are often used in combination with a pictogram in the text to clarify the source of the
danger.
3
1 Marking of the Safety and Warning Signs
ELECTRICAL VOLTAGE!
This sign is a warning for electricity.
It is posted for all work and operating procedures that are to be observed precisely in order to
prevent danger to persons and the system by electricity.
ATTENTION! Danger of damage to robot or property.
This sign indicates information that, if disregarded, presents a danger to the robot system,
individual modules, or the operating environment. There is no risk of injury.
Wear protective clothing.
Wear your personal protective equipment:
Safety shoes, protective helmet, safety goggles, and work gloves.
Danger of environmental damage.
This sign indicates information that, if disregarded, presents a danger to the environment. There
is no risk of injury.
4
2 General Safety Information
2
Safety
2.1
General Safety Information
The HORST robot system is a quality product manufactured in accordance with the recognized rules of
technology. The robot system left the manufacturing plant in perfect condition in terms of safety.
The robot system is designed and built according to the current state of the art in safety technology.
However, there is always a residual risk!
For your own safety, always observe the following:
WARNING!
Incorrect operation or handling of the robot system can lead to severe personal injuries.
 In order to avoid damage, these Assembly Instructions must be read, understood, and
observed.
 Persons who work with the robot system must be familiar with the safety information of
these Assembly Instructions and act according to them.
 Always observe the currently valid safety regulations and -information.
 Make sure to observe the occupational safety regulations specified by the law, the regulatory
agencies, and the professional associations.
2.2
Proper Use
The HORST robot system is used to implement industrial robot applications and robotics applications in
the area of education. After being programmed by the operator, the robot system is able to execute movements independently. Add-on parts such as grippers or testing instruments can be attached to the robot.
These can be controlled by the robot system.
The robot system must be operated only in dry, level interior spaces on a firm surface. The robot must be
used only within suitable protection devices (e.g. separating protection device, light curtain, or safety laser
scanner).
Note:
−
The robot system must be used as intended and only in accordance with the Assembly Instructions (AI) and the enclosed documents. All information and safety instructions of the AI for the
operating personnel must be observed. Any use that differs from or extends beyond this is
considered improper and is expressly prohibited.
−
In addition, the operator must observe and provide instruction on generally applicable legal and
other binding regulations on accident prevention and environmental protection.
−
All protection devices must be functional in order for the robot system to be used properly.
−
Changes to or conversions of the robot system must not be made without the manufacturer’s
approval.
DANGER!
The robot system must not be used in rooms with a potentially explosive atmosphere.
5
2 Improper Use
2.3
Improper Use
Any use that is not described in section 2.2 or goes beyond it is considered improper use.
2.3.1
Foreseeable Misuse
The robot system is not intended for hazardous applications. Any use or application that deviates from
the intended use is considered as impermissible misuse.
In the case of foreseeable misuse or improper handling of the robot system, the manufacturer’s
declaration of incorporation expires, as a result of which the operating permit also expires automatically.
Examples of foreseeable misuse include the following:
−
Cutting and welding of workpieces
−
Coating/painting
−
Use in contact with any kind of liquids (except lubricants intended for the robot system)
−
Use in potentially explosive atmospheres
−
Use in medical and life-critical applications
−
Use prior to the implementation of a risk assessment of the entire application
−
Use with applications with insufficient response times of the safety functions
−
Use as a climbing aid
−
Operation outside of the permissible operating parameters
−
Use of the robot system by personnel who have not received the appropriate instruction, training, or authorization
−
Operation of the robot system outside of the specified technical limits
−
Use of components that have not been approved by the manufacturer
−
Repairs to components performed by unauthorized personnel
−
Manipulation of power settings
−
Attachment of accessories or add-on parts that are not expressly approved for use by the manufacturer
−
Removal or manipulation of protection devices, e.g. covers or speed restrictions
−
Use of unsuitable aids, e.g. tools or lifting gear, operation of the robot system with defects
−
Implementation of maintenance activities without shutting down the robot system according
to the instructions
These forms of misuse by operating personnel or third parties are strictly prohibited:
6
−
The load capacity of the robot must not be exceeded.
−
Sensors must not be covered, masked off, or otherwise disabled. The configuration of sensors
must not be changed under any circumstances.
−
The enabling switch and other actuating elements must not be bypassed or otherwise manipulated or disabled.
−
Work must be performed only in the operating mode which is appropriate for the respective
situation.
−
The robot must be used only within suitable protection devices (e.g. separating protection device, light curtain, or safety laser scanner).
2 Operator’s Duties
2.4
Operator’s Duties
2.4.1
EU Declaration of Conformity and Declaration of Incorporation
The robot system is considered partly completed machinery in accordance with the EC Machinery Directive. The robot system must be commissioned only under the following conditions:
1.
All safety functions and protection devices required for final machinery as defined by
the EC Machinery Directive have been added to the robot system.
Or:
2.
The robot system is integrated in a system.
Or:
3.
The robot system forms a system together with other machinery.
−
This system or machinery must correspond to the provisions of the EC Machinery Directive. A CE declaration of conformity must be present. The operator is
solely responsible for ensuring this.
Declaration of Conformity
The operator must prepare a declaration of conformity in accordance with the EC Machinery Directive for
the entire machinery; this constitutes the basis for a corresponding CE marking.
Declaration of Incorporation
The robot system is delivered as partly completed machinery with a declaration of incorporation in accordance with Annex II B of the Machinery Directive 2006/42/EC.
The declaration of incorporation declares that the commissioning of the partly completed machinery remains impermissible until the partly completed machinery is installed in a piece of machinery or assembled together with other parts into a piece of machinery that corresponds to the provisions of the EC
Machinery Directive, and the EC declaration of conformity in accordance with Annex II A is present.
This includes in particular that corresponding protective measures according to the risk assessment performed by the operator are taken and that these are to be verified and validated. To this end, the robot
system offers a defined scope of safety functions. Emergency stop and safety stop I/Os are prepared in
accordance with EN ISO 10218-1.
The operator must ensure the correct function of external protection devices.
2.4.2
Risk Assessment by the Operator
DANGER!
Add-on parts, workpieces, or combining the robot system with other pieces of machinery can
increase dangers or create new dangers.
 In order to ensure safety, robot system HORST must be installed in accordance with the
guidelines specified in the standards DIN EN ISO 12100 and DIN EN ISO 10218-2.
 After you have assembled the robot system or integrated it in a system, perform a risk assessment for the entire system.
To prevent dangers, additional protection devices (e.g.separating protection device, light curtain, or safety
laser scanner) must be installed.
The risks listed below in particular must be observed:
7
2 Operator’s Duties
2.4.3
−
Crushing, impact, and cutting injuries:
− Between the axes of the robot
− Between the robot and the mounting surface
− Between the linkage of the robot
−
Crushing and cutting injuries:
− Between the robot/tool and other objects
− Between the robot/tool and solid surfaces
−
Impact injuries caused by the robot
−
Crushing and cutting injuries caused by sharp edges:
− Of the robot
− Of the tool
− Of workpieces
−
Tilting or falling of the robot.
− During transport
− During assembly
− During operation (due to insufficient attachment)
−
Tools/workpieces being flung around or falling down (due to incorrect assembly, design, programming, or interruption of the energy supply to the robot or end effector)
−
Electrical danger in case of contact between modules and liquids.
−
Danger of falling due to lines lying around.
−
Danger due to incorrect integration in the control system of an overall system.
−
Danger due to incorrect integration in the superordinate emergency stop circuit.
Operations Manager
DANGER!
Possible personal injuries caused by unsafe condition of the system
 The operator of the robot system is obligated to designate an operations manager at the
installation location.
 The operations manager is obligated to operate the robot system only in perfect and safe
condition.
In addition, the operations manager is obligated:
−
to only let persons work on the robot system who are familiar with the fundamental regulations
on occupational safety and accident prevention and who have been trained in handling the
robot system by fruitcore robotics GmbH or by personnel authorized by fruitcore robotics
GmbH.
−
to only let persons who have read and understood the AI, and confirmed this with their signature, to work on the robot system (see Work and Safety Briefing).
−
to clearly determine the responsibility of the personnel for operating, converting, repairing, and
maintaining.
−
to supervise the safety-conscious behavior of the personnel.
−
to encourage the transport and operating personnel to wear protective clothing.
−
to provide the personnel with the necessary safety equipment.
The operations manager must conduct checks as to the safety-conscious and danger-conscious
behavior of the operating and maintenance personnel.
8
2 Operating Personnel
2.5
Operating Personnel
2.5.1
Obligation of the Operating Personnel
Before taking up work, all persons commissioned with working on the robot system undertake:
2.5.2
−
to observe the fundamental regulations on occupational safety and accident prevention.
−
to read the AI and confirm this with their signature.
−
to follow the instructions and safety information of the AI.
−
to check the robot system in terms of safety and proper function before starting work.
−
to contact the operations manager or fruitcore robotics GmbH in case of questions.
Training of the Operating Personnel
DANGER!
Possible personal injuries caused by untrained operating personnel
 The operating personnel must be trained on the work with and dangers of the robot system
by fruitcore robotics GmbH or authorized personnel commissioned by fruitcore robotics
GmbH.
 Persons who have not received this training are not permitted to operate the robot system.
DANGER!
Possible personal injuries caused by the operation of persons undergoing training
 Persons to be trained or taught as well as apprentices are only permitted to operate the robot
system if supervision by a trained person with technical or electrotechnical training (teaching
personnel) is ensured.
The operating personnel must be trained on the work with and dangers of the robot system by fruitcore
robotics GmbH or authorized personnel commissioned by fruitcore robotics GmbH.
The operating personnel must be at least 18 years old and both physically and mentally fit to operate the
robot system.
Instructed personnel with technical training may be used for the following activities:
−
Operating the robot system in automatic mode
−
Adjusting the system parameters (teaching modes T1 and T2)
Instructed personnel with technical and electrotechnical training may also be used for the following activities:
2.6
−
Assembly and commissioning of the robot system
−
Troubleshooting and fault rectification
−
Inspection, maintenance, and repair
Working Area, Danger Zone, and Safe Area
The working area is a defined 3D space within the range of the robot. When tools, measuring devices, and
workpieces are attached, the range of the robot and therefore its working area change.
The stopping distance is calculated on the basis of the reaction distance and braking distance of the
robot.
The danger zone includes the working area and stopping distance of the robot. Persons must not be in
the danger zone while the robot is in operation.
9
2 Safety Functions
DANGER!
Due to the robot’s automatic movement, sudden dangers must be expected within the danger
zone. Moving modules may cause personal injury or property damage.
 The robot system must be operated only in technically perfect condition and with active
safety equipment.
 The robot must be used only within suitable protection devices (e.g. separating protection
device, light curtain, or safety laser scanner). The protection devices must stop the robot’s
movement within the danger zone.
The safe area is located outside the danger zone. Persons may be in this area during all operating modes.
2.7
Safety Functions
The robot control is equipped with two different types of safety functions, both of which bring the robot
into a safe condition. A safe state is achieved by braking all of the robot’s drive axles.
The two fundamental emergency stop and safety stop safety functions are described below.
Emergency Stop
Bringing about a safe condition of the robot in the event of an emergency situation. This safety function
is available in all operating modes. It takes precedence over all safety functions. It is triggered by the
emergency stop button or external safety controls. External emergency stop devices are connected to the
emergency stop inputs of the switch cabinet, hereinafter referred to as the horstCONTROL.
This safety function must be used in emergency situations exclusively in order to bring the robot into a
safe condition. The emergency stop must not be used for process-related stops.
Safety Stop
Bringing about a safe condition of the robot for process-related and safety-critical situations. This safety
function is to be used for process-related stops during which operating personnel must be able to intervene in the danger zone.
The purpose of both types of safety functions is to bring about a safe condition of the robot.
The safe condition is marked by the following properties:
−
Emergency stop: A category 1 stop is triggered. The robot is braked actively until it comes to a
standstill; the brakes are applied, and the energy of the drives is then switched off.
−
Safety stop: A category 2 stop is triggered. The robot is actively braked until it comes to a
standstill. The drive power is not switched off. The safe standstill is monitored.
The robot control has other safety functions. These are described in the subsections on the configurable
safety functions from page 37.
The safety-related performance of the control system corresponds to PL “d” with structure
category 3 according to DIN EN ISO 13849-1:2006. It is defined by the risk assessment of the
robot system or DIN EN ISO 10218-1.
10
2 Safety Information for Assembly and Commissioning
2.8
Safety Information for Assembly and Commissioning
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
 Work on the electrical equipment must be performed only by specialist personnel with appropriate training and in accordance with the electrotechnical rules.
 Make sure that the power supply is switched off while working on the robot and that it cannot
be switched on again by accident.
 Use only the included cables to connect to the power grid. Do not use damaged cables.
DANGER!
Danger due to incorrect assembly and commissioning
 Assembly and commissioning must be performed only by persons with technical and electrotechnical training who were also authorized by fruitcore robotics GmbH.
DANGER!
Danger due to missing protection devices and safety equipment as well as defective/damaged
modules or accessories.
 Only commission the robot system with functional protection devices and safety equipment
as well as functional modules or accessories.
WARNING!
Danger of impact and crushing due to robot movement
 Close off the installation area, and protect it against access by unauthorized persons.
 Secure the horstPANEL (operating panel) and horstCONTROL against operation by unauthorized persons.
CAUTION!
Risk of injury due to overloading or the robot falling
 The robot must be lifted by at least two persons in order to prevent overloading or the robot
from falling.
CAUTION!
Damage due to the formation of condensate
Never switch the robot on immediately if it has been brought from a cold environment into a
warm environment. The condensate that forms in these conditions could damage the electronics. We recommend leaving the system overnight to adjust to the ambient temperature.
11
2 Safety Information on Operation
2.9
Safety Information on Operation
 Make sure that the robot arm and the tool are screwed on properly and safely.
 Ensure that there is sufficient room for the robot arm to move freely. There must be no obstacles in the working area.
 The mounting surface of the robot must be stationary within a firmly installed protection device.
 Note that the range of the robot and thus the danger zone change with add-on parts and workpieces.
 If the robot is combined with other machinery in a system, make sure that the other machinery
cannot damage the robot.
 Do not expose the robot system to permanent magnetic fields. Very strong magnetic fields can
damage the robot system.
 Ensure that suitable protection devices (e.g. separating protection device, light curtain, or
safety laser scanner) were installed. The protection devices must stop the robot’s movement
within the danger zone. Check the protection devices for proper function every day.
 Do not enter the danger zone of the robot during operation, and do not touch the robot.
 Only operate the robot system in undamaged condition. Never modify the robot system.
fruitcore robotics GmbH excludes any liability if the product has been modified.
 Check the emergency stop and safety stop functions daily.
 The robot system must be checked for externally visible damage and defects at least once per
day/shift. Changes or damage that have occurred must be reported to the person or office
responsible immediately.
DANGER!
Possible personal injuries caused by careless handling of the system.
 Refrain from any unsafe method of working!
 In the event of malfunctions, switch off the robot system immediately and secure it
against restarting, including by third parties. Report malfunctions immediately to the operations manager and rectify or have them rectified immediately.
 Only perform switch on and switch off processes in accordance with the Assembly instructions.
 It is only permissible to disconnect the horstPANEL from or connect it to the horstCONTROL
when it is disconnected from the power supply.
 Ensure that only the connected horstPANEL is in the vicinity of the robot to avoid confusions
with inactive emergency stop buttons.
2.9.1
Emergency Situations
DANGER!
Due to the robot system’s automatic movement, sudden dangers must be expected within the
danger zone. Moving modules may cause personal injury or property damage.
 The robot system must be operated only in technically perfect condition and with functional
protection devices.
 The robot must be used only within suitable protection devices (e.g. separating protection
device, light curtain, or safety laser scanner).
12
2 Safety Information on Operation
In the event of an emergency, the robot system must be stopped with the emergency stop button (see
subsection Emergency Stop Button, page 24).
When integrated in a complete system, the robot system must be integrated in the emergency
stop circuit of the higher-level system. Observe the information on this in subsection Safetycritical Inputs/Outputs, page 35.
2.9.2
Emergency Operation – Moving the Robot without Drive Power
The axes of the robot must be moved without drive power only in emergencies, in particular for the purpose of freeing persons. The personnel performing the rescue operation must have undergone basic
technical training and observe the following warnings and instructions. Specialist personnel from fruitcore
robotics GmbH must be called for recommissioning the system.
WARNING!
Danger of impact and crushing due to robot movement
Unintended movement of the robot may occur due to the release of internal stress or gravity.
 Secure the robot arm against unintended movement.
13
2 Safety Information on Operation
WARNING!
Danger of impact and crushing due to unexpected robot movement
 Remove any workpieces from the gripper.
 Disconnect the robot system from the power grid.
 Disconnect any assembled tools that are operated with compressed air from the compressed air supply.
 Close off the danger zone and protect it against access by unauthorized persons.
 Set up warning signs to prevent the system from being started up while work is being performed. Secure the horstPANEL and horstCONTROL against operation by unauthorized persons.
 Hold the robot arm by the swivel arm, exactly between axis 2 and axis 3 (see arrow in figure
below). Ensure that no body parts can come between the moving axes of the robot.
 Now move the robot arm with a powerful movement in the desired direction.
Axis 4
Axis 3
Axis 5
Axis 6
Axis 2
Axis 1
 Then secure the robot arm again against unintended movements.
Attention: The warranty expires when this action is performed and the robot system must
only be started up again after consultation with fruitcore robotics GmbH.
DANGER!
Defective and damaged components and modules / faulty assembly
After manual movement of the robot arm, the robot system must not be started up again. This
could result in significant personal injuries.
 Contact fruitcore robotics GmbH
14
2 Safety Information for Fault Rectification, Cleaning, and Maintenance Work
2.10 Safety Information for Fault Rectification, Cleaning, and Maintenance Work
DANGER!
Danger resulting from incorrect fault rectification and maintenance
 Fault rectification and maintenance must be performed only by persons with technical and
electrotechnical training who were also authorized by fruitcore robotics GmbH.
DANGER!
Danger of electric shock
 The connection and any work on the electrical equipment must be performed by electrotechnical specialist personnel only.
WARNING!
Danger of impact and crushing due to unexpected robot movement
 Remove any workpieces from the gripper prior to cleaning or maintenance.
 Prior to carrying out cleaning or maintenance work, disconnect the robot system from the
power grid and disconnect any mounted tools that are operated with compressed air from
the compressed air supply.
 Close off the danger zone and protect it against access by unauthorized persons.
 Set up warning signs to prevent the system from being started up while work is being performed. Secure the horstPANEL and horstCONTROL against operation by unauthorized persons.
WARNING!
Danger due to missing protection devices as well as defective/damaged modules or accessories.
 Assemble all protection devices after completing the work. Check all modules and accessories.
 After completing the maintenance work, perform a test run of the entire system, and check it
for proper functioning.
Read the Assembly Instructions!
Refer to the Assembly Instructions and any the accompanying documentation for information
on maintaining the robot system.
Maintenance and inspection intervals stipulated in the Assembly Instructions, including the
replacement of wear and spare parts, must be observed.
Spare parts must correspond to the technical requirements specified by fruitcore robotics
GmbH. This is always guaranteed with original spare parts.
2.11 Residual Danger
The robot system is built according to the current state of the art and in line with the recognized safety
rules. Nevertheless, danger to the user or third parties or impairments of the system and other material
assets may arise in the course of use.
15
2 Residual Danger
DANGER!
Danger resulting from human error or malfunctions
 When integrated in a complete system, the robot system must be integrated in the emergency stop circuit of the higher-level system.
WARNING!
Operation without protection devices presents a risk of injury
 The robot must be used only within suitable protection devices (e.g. separating protection
device, light curtain, or safety laser scanner).
 All protection devices must always be completely assembled and functional. The protection
devices must be removed only while maintenance work is being performed by the maintenance personnel.
Improper use of the robot system may result in the following dangers:
RISK
OF
The robot generates heat during operation.
BURNS!
 The robot must not be touched during or immediately after operation.
 After switching off the robot, wait until it has cooled down or wear heat protection gloves.
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
 Work on the electrical equipment must be performed only by specialist personnel with appropriate training and in accordance with the electrotechnical rules.
 Make sure that the horstCONTROL or the cables do not come into direct contact with liquids.
This may result in electric shocks with a significant health risk or even death.
 Prior to performing any work on the electrical equipment, disconnect the robot system from
the power grid.
 In the event of malfunctions of the electrical equipment of the robot system, switch off the
robot system immediately and rectify the malfunction.
 The electrical equipment of the robot system must be checked regularly. Defects such as
loose connections or damaged cables must be rectified immediately.
DANGER OF CRUSHING, IMPACT AND CUTTING!
Possible personal injuries due to unexpected movement of the robot system during maintenance work
If the energy supply to the robot system is stopped, the engine brake of the respective robot
axis is applied. Since the belt drives are elastic, they may still move slightly. As a result, manual
intervention can lead to injuries even in idle mode.
 Never insert your hand into the area of motion or between the axes of the robot.
16
2 Residual Danger
DANGER OF CRUSHING, IMPACT AND CUTTING!
Possible personal injuries due to the robot arm collapsing during maintenance work
If a belt tears unexpectedly, the robot arm may collapse.
 During maintenance work, the robot arm must be sufficiently secured against collapsing.
 Do not stand under the robot arm.
 Never insert your hand between the axes of the robot system.
DANGER OF EJECTION OF PARTS!
Possible personal injuries due to unexpected ejection or dropping of parts during maintenance
work
 Ensure that tools or components are attached securely to the robot.
 Only move workpieces if they are gripped safely.
 If possible, perform commissioning, maintenance, and cleaning work only when no workpiece
is in the gripper.
 The operator must perform a risk assessment for the entire system. If there is a danger of
ejection, protection devices that provide protection against ejected parts must be used.
17
3 Residual Danger
3
Transport
CAUTION!
Risk of injury due to overloading or the robot falling
 The robot must be lifted exclusively at the swivel arm by at least two persons in order to
prevent overloading or the robot from falling. If possible, the robot must be transported securely attached to a suitable mobile stand.
 You must prevent the robot from tilting. The robot must be lifted carefully and simultaneously
by two people.
ATTENTION!
Risk of damage to the robot.
 Only hold the robot by the swivel arm.
 Do not move the robot axes with force.
When delivered, the robot is in transport position (see figure below).
1 Robot
2 Swivel arm (hold at the arrow)
2
1
Fig. 3-1: Transport position
To transport the robot system again after use, follow the steps below:
 Before disconnecting the robot system from the power supply, start the “Shipping position”
program in horstFX and leave it to run in full. This brings the robot to the correct position for
shipping/transport.
 Alternatively, use the Freies Fahren (free movement) software control to bring the robot to the
transport position, as shown in the illustration above (see the horstFX user manual, section
“Free movement”)
 Disassemble the robot system from the mounting surface (see subsection Disassembly, page
69).
 Securely package the robot, horstPANEL, and horstCONTROL.
 During further transport, the robot system must be secured against toppling over and falling
down.
ATTENTION!
For transport, the robot system must be in the original packaging from fruitcore robotics GmbH.
18
4 Scope of Delivery
4
Description of the Robot System
In this section, we will describe the robot system and its components.
4.1
Scope of Delivery
The robot system is delivered with:
−
HORST robot
−
horstCONTROL (switch cabinet)
−
horstPANEL (portable operating panel)
−
Connection cable (robot – horstCONTROL), 3 m
−
Power cable (1.8 m)
−
DVI cable (5 m)
−
4 mounting screws (DIN 7984 M8x20)
−
Mount for control panel
−
Assembly Instructions
−
Surfstick incl. SIM card (not included with the HORST600light)
19
4 Modules
4.2
Modules
In this subsection, the main modules of the robot system are presented. The most important components
are listed and some are explained in more detail.
4.2.1
Robot
Fig. 4-1:
20
Robot HORST 600
1
Base – fixed part with floor flange
2
Base – moving part
3
Swivel arm
4
Support arm 1
5
Support arm 2
6
Support arm 3
7
Tool flange
4 Modules
Robot axes
The movements are realized via the rotation around 6 robot axes.
Fig. 4-2:
Robot axes
You can find the values for the ranges of movement in the Annex Technical Data, page70.
4.2.2
horstPANEL (operating panel)
1
Touch display (user interface)
2
Connection to horstCONTROL
3
Emergency stop button
1
2
3
The horstPANEL features a portable
operating panel equipped with a touchscreen
display. It is connected to the horstCONTROL
by a DVI cable.
As standard, a 5 m long DVI cable is supplied.
Up to 15 m are possible after consultation
with fruitcore robotics GmbH.
Fig. 4-3: horstPANEL operating panel
21
4 Modules
4
2x USB 2.0 ports
5
Enabling switch
The enabling switch and two USB 2.0 ports
for connecting additional input devices
(keyboard, mouse) are located on the rear.
The USB ports on the horstPANEL are
intended only for connecting input devices.
Use the USB port on the horstCONTROL to
connect storage media.
4
5
Fig. 4-4:
Rear side of horstPANEL
In order for the robot to perform movements in teaching mode, the enabling switch must always
be kept in the center position.
WARNING!
−
Never connect a standard monitor to the DVI cable! As the wiring does not correspond to
the standard, this could damage the end device or the horstCONTROL!
−
Never plug in or unplug the horstPANEL during operation! Switch the horstCONTROL off
first.
−
The USB ports on the horstPANEL are only provided for input devices. For storage media,
use the interfaces of the horstCONTROL
Fig. 4-5: Mount for horstPANEL
The mount (1) for the horstPANEL is used for desktop installation (2).
Use the mount for the horstPANEL e.g. in teaching mode, to prevent having to hold the
horstPANEL by hand for a long time.
22
4 Modules
4.2.3
horstCONTROL (switch cabinet)
The horstCONTROL is the robot’s control system. The main control (horstIO) is installed in this switch
cabinet. Countless interfaces also enable communication with and control of other machines and external sensors and actuators.
The left-hand image shows the front side of the horstCONTROL, and the right-hand image shows the rear
side.
Fig. 4-6:
horstCONTROL switch cabinet
1
Cable duct for inputs/outputs (interfaces)
2
PROFINET connection (modular plug RJ45) (optional)
3
Robot connection
4
horstPANEL connection
5
PC ON/OFF button
6
Operating modes selector switch
7
Main switch
8
Connection 2x USB 3.1 port
9
Ethernet port (modular plug RJ45)
10
Power Connection
23
4 Protection Devices
4.3
Protection Devices
4.3.1
Enabling switch
The enabling switch is executed in three stages. The center position is “active”.
1
Enabling switch
1
The enabling switch is on the rear side of
the horstPANEL.
Fig. 4-7:
4.3.2
Rear side of horstPANEL
Emergency Stop Button
When integrated in a complete system, the robot system must be integrated in the emergency
stop circuit of the higher-level system.
Observe the information on this in subsection Safety-critical Inputs/Outputs, page 35.
1
Emergency Stop Button
1
The emergency stop button is on the top
right-hand side of the horstPANEL.
Fig. 4-8:
4.4
Emergency stop button
Add-on Parts & Tools (Option)
Add-on parts can be additional mechanical attachments, such as flange plates (e.g. for mounting pneumatic accessories) or tools such as grippers.
To mount tools on the mechanical interface, a standard tool flange is installed in accordance with DIN EN
ISO 9409-1 (for dimensions, see Assembling Add-on Parts, page 28).
To mount add-on parts, mounting points for flange plates are provided on the robot arm, see Annex
Optional Accessories, page75.
DANGER!
Add-on parts an increase hazards or create new hazards.
 After assembling add-on parts, perform a risk assessment for the entire system. Additional
safety precautions may be required based on this.
24
5 Working Area of the Robot
5
Assembly
5.1
Working Area of the Robot
The following figures display the size and shape of the working area.
Fig. 5-1:
Side view of working area
Fig. 5-2:
Plan view of working area
25
5 Assembly of the Robot
5.2
Assembly of the Robot
DANGER!
Danger due to incorrect assembly and commissioning
 Assembly and commissioning must be performed only by persons with technical and electrotechnical training who were also authorized by fruitcore robotics GmbH.
CAUTION!
Risk of injury due to the robot falling
 Secure the robot against tilting until it is attached to the mounting surface.
ATTENTION!
Risk of damage to the robot.
 Only lift the robot by the swivel arm.
 Do not move the robot axes with force.
For the specifications regarding the condition of the mounting surface, see the following
subsection.
Note before setting up:
 Check the modules for damage. Do not mount/use damaged parts.
 Ensure that there is sufficient room for the robot arm to move freely. There must be no obstacles in the working area.
 If the robot is combined with other machinery in a system, make sure that the other machinery
cannot damage the robot.
 Ensure that suitable protection devices (e.g. separating protection device, light curtain, or
safety laser scanner) are installed. The protection devices must stop the robot’s movement
within the danger zone.
 Protection devices (emergency stop, safety stop) must be connected only to safety-critical interfaces and must be designed to be redundant.
5.2.1
Mounting Surface
The robot must be mounted on a suitable, level, firm, dry, vibration-free, and non-moving surface with
mounting screws. The mounting surface should be made of steel or aluminum or possess comparable
strength values.
The load-bearing capacity of the mounting surface must be at least five times the weight of the robot and
nine times the maximum tilting moment of the robot with load capacity (320 Nm). The maximum load
capacity is taken into account in these values.
The robot is not designed for movement on a linear axis or a moving platform. Permissible acceleration
torques must be requested from the manufacturer, fruitcore GmbH. The robot must be assembled on a
level surface with a maximum tilt of 5°. Wall or ceiling-mounting only on consultation with fruitcore robotics GmbH.

26
5 Assembly of the Robot
5.2.2
Assembling the Robot
Fig. 5-3:
Base plate – Mounting and positioning holes
 Prepare the mounting surface according to the drilling pattern (see Fig. 5-3).
 Lift the robot by the swivel arm and position it on the prepared mounting surface.
 Secure the robot against tilting until it is attached to the mounting surface.
 Align the robot with pins via the positioning holes.
 Attach the robot with the 4 mounting
screws supplied (DIN 7984, M8x20)
with 20 Nm.
Fig. 5-4:
5.2.3
Fastening the mounting screws
Restricting the Movement Space
ATTENTION!
Risk of damage to the robot.
 Ensure that the movement space is limited by the software and never drive into the mechanical end stops of the robot.
If the robot is intended for operating mode “Manual with high speed (T2)”, the integrator must provide a
limited space to reduce the size of the danger zone. The movement space must also be limited by the
software, see horstFX user manual, subsection Axis restriction)
27
5 Assembling Add-on Parts
 The stop bolt (1) is at the rear of the base
 Undo the screws (2) of the cover
 Remove the cover (3)
 Bring the robot into position
so that the thread of the desired
stop position is accessible from above
 Mount the screw (4)
DIN 912 M8x12 / Steel 8.8, galvanized
(not included in scope of delivery)
at the desired position
 Secure the cover again
Fig. 5-5:
5.3
Sketch of mechanical axis
limitation for axis 1
Assembling Add-on Parts
Add-on parts such as grippers or testing instruments can be attached to the robot.
WARNING!
Change of the danger zone due to add-on parts
 Note that the range of the robot and thus the danger zone change with add-on parts.
WARNING!
Danger due to the add-on parts and workpieces being ejected during operation
 Before commissioning, ensure that the add-on part is securely attached.
 Avoid eccentric loads to prevent upswing.
 Adhere
to
the
holding
forces
adapted
to
the
process
The robot is equipped with an interface
for add-on parts. It has four holes with an
M6 thread for attaching the add-on parts.
For accurate assembly, the Ø6 hole can
be used with a pin.
Fig. 5-6:
28
Tool flange drawing
parameters.
5 Setting Up horstCONTROL
Refer to the Annex for information on optional add-on parts from fruitcore robotics GmbH.
For information on add-on parts from third-party manufacturers, refer to their documentation.
Add-on parts (e.g. pneumatic valves) can be fitted on the robot arm after consultation with
fruitcore robotics GmbH.
ATTENTION!
Note when routing pneumatic valves and lines:
 During attachment, the risk of collision with other modules must be taken into consideration.
 The lines must not be crushed or torn off by the robot’s movements, and they must be secured against detaching (possibly with cable ties or the like).
5.3.1
Pneumatic Connection of Add-on Parts
ATTENTION!
Cables laid on the robot arm must be secured against loosening.
The pneumatic connection values can be found in the documentation from the manufacturer of
the add-on parts.
 When all pneumatic components (gripper, cables, valves) are securely mounted, connect the
compressed air supply.
5.4
Setting Up horstCONTROL
 Position the horstCONTROL in compliance with the following:
− The connection cable can be routed to the robot.
− It is protected against damaged and falling down.
− There is 100 mm of free space on all sides (the ventilation slots must be free).
− Accessibility of the switches and connections only from outside the protected area is
ensured.
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
 Make sure that the cables and the horstCONTROL do not come into direct contact with liquids.
 The horstCONTROL must not be used in dusty or humid environments that exceed protection
classification IP20. Conductive dust in particular must be avoided.
Refer to the technical data for the length of the included cables.
29
6 Electrical System Warning Notes
6
Electrical Installation
This section describes the electrical installation of the robot system, i.e. the connection of the robot to
the switch cabinet (horstCONTROL) as well as the connection of other devices and systems.
There are several electrical interfaces:
−
Robot connection: Connection of the robot to the horstCONTROL (switch cabinet)
−
Power connection: Connection to the power supply
−
horstCONTROL I/O: Connection of external devices and systems to the switch cabinet
−
Tool I/O: Connection of tools to the robot arm
−
Computer interfaces
The safety and warning notes in the following section apply to all electrical interfaces.
6.1
Electrical System Warning Notes
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
 Work on the electrical equipment must be performed only by specialist personnel with appropriate training and in accordance with the electrotechnical rules.
 Use only the included power cable to connect to the power grid. Do not use damaged cables.
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
 Make sure that the power supply is switched off while working on the robot and that it cannot
be switched on again by accident.
DANGER!
Danger due to incorrectly connected emergency stop devices
 Only use the interface for emergency stop I/O to connect external emergency stop devices.
Do not connect any emergency stop devices to normal I/O or to the safety stop I/O.
DANGER!
Danger due to incorrectly connected safety stop devices
 Only use the interface for safety stop I/O to connect external safety stop devices (e.g. safety
laser scanners). Do not connect any safety stop devices to normal I/O or to the emergency
stop I/O.
WARNING!
EMC problems may occur due to incorrect grounding.
 When grounding the robot system, ensure corresponding protective and functional measures
as per DIN VDE 0100 and EMC Directive 2014/30/EU.
 Ensure that the robot system is properly grounded. I.e. there must be a shared electrical connection between all elements belonging to the system and ground.
30
6 Robot Connection
WARNING!
Trip hazard
 Ensure that the cables and hoses for media and power supply are properly laid and secured.
WARNING!
Unexpected movements of the robot
 Only connect the power supply when you are certain that assembly has been fully completed
and is correct.
ATTENTION!
Only use the original cables supplied with the robot system. Do not use the robot for
applications that expose the cables to bending.
6.2
Robot Connection
 Connect the robot to the horstCONTROL using the connection cable.
Fig. 6-1: Interface on the robot
1
Robot connection to horstCONTROL
1
Fig. 6-2: Robot connection to horstCONTROL
ATTENTION!
The robot connection cable must be plugged into the horstCONTROL before the power is
switched on. It must only be plugged in or disconnected in a deenergized state.
The robot must never be disconnected during operation.
The cable must not be extended or opened.
31
6 Power Connection
6.3
Power Connection
The horstCONTROL power connection is a standard IEC C14 male socket (IEC-60320) with integrated
pull-out protection. The supplied power cable has a safety plug at one end and an IEC C13 cold-device
coupling with specially molded housing at the other end. This, together with the pull-out protection, ensures reliable connection to the power supply. Therefore, always used the power cable supplied.
The power supply must have:
−
Main fuse
−
Circuit breaker
−
Ground connection (PE protective conductor)
.
The horstCONTROL is equipped with a power entry filter and a 6.3 A fuse.
 Connect the horstCONTROL to the
power supply with the supplied power
cable. Lay the power cable such that it
is protected against damage.
Fig. 6-3:
Power connection to horstCONTROL
Parameter
min.
typ.
max.
Unit
Input voltage
90
-
260
VAC
Input frequency
47
-
63
Hz
4.4
A
Current consumption
Rated power draw 1
210
W
Table 6-1: Mains connection characteristic values
1)
Power draw measuring conditions: horstCONTROL PCA, Robot H600, all axes moved at the same time, speed
100%, load capacity 0 kg, measuring period 2 hours
ELECTRICAL VOLTAGE!
 Ensure that all cables are connected correctly before supplying the horstCONTROL
with power. Always use the original power cable supplied.
 Make sure that the robot is grounded (power plug connected to PE protective conductor).
 A suitable circuit breaker and a suitable RCD (residual current operated device) must
be installed.
32
6 horstCONTROL I/O
6.4
horstCONTROL I/O
This section describes how to connect devices to the horstCONTROL.
The connections can be split into four categories:
−
Safety-critical inputs/outputs
−
General digital outputs
−
+24 V power supply
−
Add-on interface
The inputs and outputs for this are located on the horstIO – the main control installed in the horstCONTROL – which is accessible on the horstCONTROL after removal of the cable duct. You can find a table
overview of the connectors and their terminal assignments in the Annex 13.7 from page 79.
 Undo the four external M4 countersunk head
screws.
1
 Remove the cable duct cover (1).
 The horstIO connections are now accessible.
 If relevant, connect peripherals to the interfaces.
 Secure the cable duct cover (1) again.
Fig. 6-4: horstCONTROL cable duct
The connections are designed as pluggable screw terminal connectors. The supplied screw terminal connectors of type Amphenol Anytek TJ0831530000G (alternatively Phoenix Contact MC 1.5/ 8-ST-3.81) or
even Push-In terminals, such as Phoenix Contact FK-MCP1.5/8ST-3.8 can be used as connectors.
The connector base strip is of type Amphenol Anytek OQ0832500000G.
33
6 horstCONTROL I/O
6.4.1
Overview of All Interfaces
The following graphic shows the layout of the interfaces available on the horstIO.
Fig. 6-5: horstIO interfaces
−
7 safety-critical inputs – 2-channels each (orange area)
o
o
−
3 dedicated inputs (orange area with red font)
▪
Emergency stop input – connection of potential-free contacts only
▪
Safety stop input
▪
Internal enabling switch
4 configurable outputs (external emergency stop, acknowledgement signals, etc.)
6 safety-critical outputs, 2-channels each (orange area, black font)
o
4 configurable outputs, push-pull
o
2 configurable, potential-free outputs (two relay contacts each)
−
Test signal generation TA/TB: OSSD signal for safety-critical inputs
−
Up to 28 general digital inputs (blue area)
−
o
20 digital inputs
o
A further 8 digital inputs, if the 4 configurable, safety-critical inputs are configured as normal
inputs
Up to 30 general outputs (green area)
o
18 digital outputs, Push-Pull / High-Side
o
A further 8 digital outputs, push-pull, if the 4 configurable, safety-critical outputs are configured as normal outputs
o
A further 4 relay contacts, from the configurable, potential-free, safety-critical outputs, configured as normal outputs
−
Shared GND and +24 V terminals (red area)
−
RS-485 interface for future extensions (purple area)
−
External bridge for +24 V: can be routed via the safety relay for safety-critical switch off of digital outputs
1-16.
−
An external enabling switch can be connected via terminals ENA/ENB and TA/TB, but deactivates the internal enabling switch on the horstPANEL.
34
6 horstCONTROL I/O
6.4.2
Safety-critical Inputs/Outputs
The horstCONTROL is equipped with several safe inputs and outputs. Safe I/Os are established redundantly through two independent lines. An incident or failure of a line therefore does not result in the complete loss of the safety function.
Some of the safe I/Os are configurable to enable extended connectivity and functionality with devices and
systems. They can be assigned safety-critical functions in the horstFX software, but they can also be
used as normal digital I/Os.
The emergency stop and safety stop inputs as well as the enabling switch input are exclusively safe inputs. The emergency stop input is only intended for the connection of emergency stop devices. The safety
stop inputs apply to all kinds of safety-critical protection devices (e.g. safety laser scanners). The functional difference is explained in the following table:
Emergency stop input
Safety stop input
Active
In all operating modes
(T1, T2, Automatic)
Only in automatic mode
Robot movement stops
Yes
Yes
Energization of drives
Off
On
Program execution
Paused
Paused
Acknowledgement
Manually at the horstPANEL
Manually at the horstPANEL
Further operation after
acknowledgement
Program continues running
at interrupted position
Program continues running at
interrupted position
Requires reinitialization
No *
No *
Stop category (IEC 60204)
1
2
Power level (ISO 13849-1)
PL d
PL d
* Only if the power supply has been interrupted must the robot must be reinitialized.
Table 6-3: Functional difference between emergency stop and safety stop
DANGER!
Danger due to incorrectly connected emergency stop devices
 Never connect safety signals to a PLC that does not meet at least the corresponding protection level. This could cause the safety functions to be overridden, which could result in serious
injuries or death.
 Only use the safe inputs for emergency stop to connect additional emergency stop devices.
Do not connect any emergency stop devices to general digital inputs or safety stop inputs.
 Safety-critical I/Os always have two channels. The two channels must be kept separate to
prevent a fault from causing loss of the safety function.
 The safety functions must be tested before commissioning and at regular intervals.
35
6 horstCONTROL I/O
Output Signal Switching Device (OSSD)
For safety-critical inputs, an output signal switching device (OSSD) can be activated. With an output signal
switching device activated, the output is periodically switched off and the input read back. If the results
do not match, an error is triggered. This means short circuits and cross-circuits can be monitored.
When using the OSSD function, the internal OSSD signals must be used. When external OSSD signals are
connected, the function must be deactivated in horstFX and the input filter activated. The configurable
time of the filter must be selected such that the test impulse is ignored (filter time > test impulse).
6.4.2.1
Emergency Stop and Safety Stop I/O
The inputs for emergency stop (EIA, EIB) and safety stop (SSIA, SSIB) are available,
dedicated inputs on every horstCONTROL (Safety In 1 & 2) and therefore cannot be
configured. They are redundant with performance level “d”, category 3, as per EN ISO
13849-1 and also meet the electrical specifications of the general digital inputs, see
Electrical Parameters, page 43. The signals are at terminal block X6.
The signal for emergency stop an (Emergency In) is at terminal X6.1 and X6.3. These
are fed in from test signal TA / TB for the output signal switching device and are routed
to this terminal via the emergency stop on the horstPANEL.
In the delivery state, bridges connect these to the safe emergency stop inputs X6.2
and X6.4. An external emergency stop button can be series-connected to the emergency stop on the horstPANEL between X6.1 / X6.2 and X6.3 / X6.4.
Fig. 6-6: Emergency stop/safety
stop connection
X6.6 and X6.8 are the respective inputs for a safety stop (Safety Stop In). At
these connections, either potential-free contacts and the internal cross-circuit detection via signals TA / TB can be used, or an external safe output (e.g. safety laser scanner) can
be connected.
For the emergency stop and safety stop input, it is possible to configure an input filter in horstFX in the
Safety I/O menu. The maximum configurable time is 50 ms. See Software Configuration Options for Digital Interfaces, page 44.
The system is always in a safe state with "low" signals (0 V, logical 0), e.g. robot has a low
signal at the external emergency stop input.
If the robot has to be operated independently, bridges must be inserted in the terminals
for emergency stop, safety stop and enabling switch, see Fig. 6-6. These are inserted as
standard in the delivery state.
When integrated in a complete system, the robot system must be integrated in the
emergency stop circuit of the higher-level system.
When using an output signal switching device (OSSD), the signal is tested cyclically.
These test pulses must not cause a shut-down of all downstream control elements.
Please keep this in mind when selecting the devices to be connected.
36
6 horstCONTROL I/O
6.4.2.2
Enabling Switch I/O
The Enable input (ENA, ENB) is another dedicated input (Safety In 3), which is
intended exclusively for a three-stage enabling device (enabling switch) and
therefore cannot be configured. The enabling switch of the horstPANEL is connected to the safe inputs at terminals X3.5 and X3.7 in the lower half of terminal
block X3, and to the control system at terminals X3.6 and X3.8.
The signals at X3.5 and X3.7 are the enabling switch signals from the horstPANEL, which are fed from the test signals TA / TB (output signal switching device).
Fig. 6-7: Enabling switch
connection
6.4.2.3
Instead of the internal enabling switch on the horstPANEL, an external enabling
switch can be connected between TA / TB (X4) and X3.6 / X3.8. One bridge each
is inserted here in the delivery state. These bridges must be removed when
connecting an external enabling switch!
For the enabling switch input, it is possible to configure a filter in horstFX, see
Software Configuration Options for Digital Interfaces, page 44.
Configurable Safe Inputs
There are 4 further, configurable safe inputs SI4 to SI7 (Safety In) on terminal block X5.
These are also designed redundantly with Performance Level “d”, Category 3, in accordance with EN ISO 13849-1. They meet the same electrical specifications as the general
digital inputs. They can be used both as safety-critical inputs with different, configurable
functions, or as normal inputs.
In each case, two channels A and B are available for each safe input.
These inputs can be operated with safe OSSD outputs (for cross-circuit recognition, with
configured input filter), with internal test signals TA / TB or entirely without cross-circuit
recognition with 24 V signals.
The configuration for this is set up in the safety configuration in horstFX and sent to the
safety controller. A filter can also be configured for the configurable safe inputs,
see Software Configuration Options for Digital Interfaces, page 44.
Fig. 6-8: Connection
of safe inputs
Each time the safety configuration is changed, a new risk assessment must be carried
out!
37
6 horstCONTROL I/O
The following functions can be configured for the safe inputs (see Software Configuration Options for
Digital Interfaces, page 44):
Function
Stop
Description
category
None
-
Emergency stop
1
Signals an internal emergency stop Emergency stop output is
set.
External emergency stop
1
External system signal emergency stop. Emergency stop output
is not set.
Safety Stop
1
Protection devices that are not active in teaching mode with an
enabling switch can be connected here. This means the cell can
be entered during teaching.
Only active in automatic mode.
Safety stop
2
Like the safety stop, but automatic reset and restart of the robot
after recovery of the safe state.
Enabling switch
2
Safe stop, if enabling switch is pushed through or is not pressed.
Reduced speed
0
Checks the saved, reduced speeds. If the robot moves faster
than the reduced speed, a Stop Category 0 is triggered.
Two digital inputs
-
Safe input is configured as two general digital inputs.
Self-triggering
Table 6-4: Configurable functions for safe inputs
Here too the following applies: The system is always in a safe state with "low" signals (0 V,
logical 0), e.g. robot has a low signal at the external emergency stop input.
6.4.2.4
Safe Outputs
There are 6 configurable, safe outputs. These are also designed redundantly with Performance Level “d”, Category 3, in accordance
with EN ISO 13849-1, although outputs SR5 and SR6 (Safety Relay
Out) are each implemented as potential-free contacts by means of
positively controlled relays. With these outputs, it is possible to tell
other machines what state the robot is in.
The relay contacts can be loaded with 5 A and 24 V and are brought
out at terminal block X8.
The safe outputs SO1 to SO4 (Safety Out) at terminal block X7 correspond to the electrical specification of the digital outputs but are
not coupled with the total current limit (see +24 V Power Supply,
Fig. 6-9: Connection of safe outputs
page 42). These are always configured as Push-Pull outputs.
Each of these outputs can be used without OSSD function (chronologically offset 400 µs Low Impulse) or
al a general digital output.
For each safe output, two normal digital inputs can be configured as additional read-back inputs. This
enables safe switching of an external, positively controlled contactor or relay with read-back of the auxiliary contact states. An inverted or non-inverted signal can be used here. If an invalid read-back signal is
detected, a Category 1 stop is triggered.
38
6 horstCONTROL I/O
The following functions can be configured for the safe outputs (see Software Configuration Options for
Digital Interfaces, page 44):
Function
Description
None
Emergency stop
“LO”: The robot is in emergency stop (internal emergency stop or triggered by an error).
Robot stopped
“HI”: No axis is moving.
Reduced speed
“HI”: The robot is limited to a speed of 250 mm/s.
Teaching mode
“HI”: The robot is in teaching mode.
Standstill monitoring active
As release for external machines in the cell
"HI": Robot travel release is issued.
"LO": Standstill monitoring is active. There is a stop condition (in
T1/T2, the enabling switch is not actuated, emergency stop/safety
stop/error).
Enabling switch
“HI”: Enabling switch actuated (center position).
“LO”: Enabling switch not actuated or pressed.
Safety stop
Output can be used to forward the guaranteed operator protection
to other devices (within the same protection area).
Two digital outputs
Safe output is configured as two general digital outputs.
Table 6-5: Configurable functions for safe outputs
6.4.3
Test Signals A/B
The internally generated OSSD signals, hereinafter referred to as test signals A and B, are
issued at terminal block X4. These can be used to supply external protection devices with
two-channel, safe signals and return these to the control system. The parameters of the test
signal are specified in the following table:
Type
Push-Pull
Output voltage
23.5 – 24.5 V
Test pulse period
100 ms, not configurable
Test pulse duration
400 µs, not configurable
Load capacity
max. 50 µF
Table 6-6: Test signal characteristic values
Figure 6-10: Test signal connection
39
6 horstCONTROL I/O
6.4.4
General Digital Inputs
There are 20 general digital inputs available at terminal
blocks X1, X2 and X3. Inputs DI01 to DI20 (Digital In) are
+24 V input channels and correspond to IEC 61131-2
Type 1 and 3.
If the Configurable Safe Inputs, page 37 are configured
as general digital inputs, 8 further inputs are available.
An additional filter can also be configured here via
horstFX. The maximum possible duration for the general
digital inputs is 32767 ms.
The following functions can be configured for the general Fig. 6-11: Connection of general digital inputs
digital inputs (see Software Configuration Options for Digital Interfaces, page 44):
Function
Description
Not assigned
-
Start program
Starts a program from outside, flank LO – HI
Pause program
Pauses a running program, flank LO – HI
Continue program
Continues a paused program, flank LO – HI
Pause/continue program
Pauses a running program (flank LO – HI) or continues it (flank
HI – LO)
Acknowledge internal error
Acknowledges an internal error, flank LO – HI
Acknowledge emergency stop
Acknowledges an internal emergency stop, flank LO – HI
Acknowledge safety stop
Acknowledges a safety stop, flank LO – HI
Acknowledge internal error/emergency stop/safety stop
Acknowledges all errors and emergency stops/safety stop,
flank LO – HI
Reduced speed
Activates driving with reduced speed (not safety-critical from
the laser scanner’s warning area), flank LO – HI
Table 6-7: Configurable functions for general digital inputs
40
6 horstCONTROL I/O
6.4.5
General Digital Outputs
There are 18 general digital outputs available at terminal
blocks X9, X10 and X11. Outputs DO01 to DO18 (Digital
Out) are +24 V output channels and can be configured as
Push-Pull (switch to positive supply voltage and to
ground) or High-Side switches (switch only to the positive
supply voltage) via horstFX.
If the Safe Outputs, page 38 are configured as general
outputs, up to 12 further outputs are available, of which 4
are potential-free.
Each output can drive at least 640 mA if the signal is high Fig. 6-12: Connecting general digital outputs
(+24 V), and 440 mA if the signal is low (0 V). The total current limit in section +24 V Power Supply, page
42 applies.
Ohmic, capacitive and inductive loads can be switched. They are short-circuit proof and protected against
ESD as well as voltage peaks when switching inductive loads.
The following functions can be configured for the general digital outputs (see Software Configuration
Options for Digital Interfaces, page 44):
Function
Description
Not assigned
-
Emergency stop button
Exact image of the emergency stop button signal, for diagnostics
(OR function with several emergency stop buttons). For larger systems, the actuated emergency stop button is easier to identify.
ATTENTION: There may be several emergency stop inputs. If ONE
of the inputs is active, it is also the output.
Error
HI if there is at least one unconfirmed error.
Program running
HI if the program is running.
Program paused
HI if the program is paused.
Program in playback mode
HI if playback mode is active (you can see the menu to start/stop
the program on the right-hand side)
Drives switched on
HI if the motors are energized.
Ready
HI: Drives are switched on and travel release is available. There is
no stop condition.
Table 6-8: Configurable functions for general digital outputs
41
6 horstCONTROL I/O
Safe Shut-down of the General Digital Outputs
Digital outputs DO01 to DO16 are supplied by the +24 V
power supply via a bridge at X17.7/X17.8. One bridge
each is inserted here in the delivery state. If this bridge
and the associated ground connection are routed to the
connected actuators via a safety relay pair, these can be Fig. 6-13: Bridge for power supply DO01-16
switched off in a safety-critical manner (see wiring example Safe Deactivation of the Digital Outputs, page 47).
Thus these normal digital outputs can be used for safety-critical functions, if the connected actuators are
in a safe state when deenergized.
6.4.6
+24 V Power Supply
Fig. 6-14:
+24 V power supply
For the power supply to external devices, 22 +24 V connections and 24 ground connections are available.
All +24 V connections and the general digital outputs DO01-DO16 together can be loaded up to a maximum of 7 A. If the total current is briefly exceeded, the drain is limited to this 7 A, and if it is exceeded for
a longer period of time (e.g. due to short circuit) the +24 V power supply is switched off. The safety-critical
outputs as well as the digital outputs DO17-DO18 are not affected by this. In the event of a deactivation,
the power supply attempts to switch back on again after about 500 ms. If unsuccessful, a new attempt
will be started every 500 ms.
Likewise, an external +24 V power supply can be placed at
terminal X17.8 (see adjacent figure). It is therefore possible
to operate the general digital outputs DO01-16 with an external power supply if the ground connection of the external
power source is connected to the ground of the horstCONTROL. The permissible values for an external power supply
are specified in the table below:
Fig. 6-15: Feed of an external
power supply
Power supply
min.
typ.
max.
Unit
Internal: Voltage
23.5
24
24.5
V
Internal: Current
0
-
7
A
External: Voltage
15
24
30
V
External: Current
0
-
10
A
Table 6-9: Characteristic values of the +24 V power supply
42
6 horstCONTROL I/O
6.4.7
Common Features of All Digital Interfaces
6.4.7.1
Electrical Parameters
The specifications described in this section apply to all digital interfaces (safety-critical and general). The
functional wiring diagrams for the interfaces can be found in the Annex ( Functional Wiring Diagrams of
the Electrical Interfaces, page 82).
Parameter
min.
typ.
max.
-3
24
36
6.0
7.5
Unit
Description
Inputs
Voltage
Switching
threshold
V
Input voltage
V
Logical high–low
HIGH – LO
Switching threshold LO
8.5
10
V
Logical low–high
2.4
2.6
mA
Input voltage 18 – 30 V
– HIGH
Current consumption
Input resistance
3
ESD strength
kΩ
+/- 15
IEC 61131-2
kV
Human Body Model
Type
1&3
Type
PNP (High-Side) or Push-Pull, semi-conductor
Outputs
Function
Voltage
23.5
24
24.5
V
Output voltage
Current HI_PP
0
0.64
1.2
A
Per output, logically high, Push-Pull
Current LOW_PP
0
0.44
0.81
A
Per output, logically low, Push-Pull
Current HI_HS
0
0.64
1.2
A
Per output, logically high, High-Side
110
230
mΩ
Internal resistance LO
1
2.5
Ω
Leakage current
100
180
µA
ESD strength
+/- 8
Internal
resistance
HIGH
kV
Contact
Table 6-10: Characteristic values of digital I/O horstIO
43
6 horstCONTROL I/O
6.4.7.2
Software Configuration Options for Digital Interfaces
In the horstFX software, the inputs and outputs can also be configured in the Configuration of Inputs/Outputs menu under Settings & Info.
Assignment of Functions
In horstFX, functions can be assigned to the general digital I/Os and the configurable safe I/Os (Function
assignment setting). Examples include starting the program, acknowledging errors or moving at reduced
speed. For the inputs, this means that the assigned function is executed if there is a valid signal at the
corresponding input. For the outputs, it means that the assigned function is executed when the corresponding output is switched. The I/Os configured in this way are then no longer available as normal digital
inputs/outputs, as they have a fixed link with the functions. The exclusively safe inputs (emergency stop,
safety stop and enabling switch) (Safety In 1-3) cannot be assigned functions. More on this in the horstFX
manual.
Filters
For all digital inputs – safety-critical and general – a low-pass filter can be configured. Only if a signal is
present for a minimum period of time is it recognized as valid (e.g. for bouncing switches). The time value
can be set in the horstFX software under the Low-pass filter setting.
Possible values are between
44
−
1 and 50 ms for all safety-critical inputs (dedicated and configurable).
−
1 and 50 ms for all safe inputs configured as general digital inputs
−
1 and 32767 ms for all general digital inputs.
6 horstCONTROL I/O
6.4.8
Wiring Examples of Safety-critical Inputs/Outputs
This subsection provides examples of the wiring of digital interfaces on the horstCONTROL. Other examples can be found on horstCOSMOS.
6.4.8.1
Standard Safety Configuration
In the delivery state, the control system is configured
for sole operation of the robot. This means that no further customized, safety-critical devices are connected
to the control system. For the mandatory functions
−
Emergency stop
−
Safety stop
−
Enabling switch
bridges are plugged into connectors X3 and X6 for this
purpose, see adjacent figure.
6.4.8.2
Additional Emergency Stop Buttons
Fig. 6-16: Standard safety configuration
One or more additional emergency stop buttons should be used, which cause the robot to stop in an
emergency. The adjacent figures clarify the connection of further two-channel emergency stop buttons,
which are series-connected to the button on the horstPANEL.
Fig. 6-17: Connection of external emergency stop
button
6.4.8.3
Fig. 6-18: Connection of several external emergency
stop buttons
Safety Relay
A safety relay should be safely actuated and contactor
monitoring should be set up. The two inputs of the relay
are connected to channel A and channel B of e.g. Safety
Out 1. Contactor monitoring can be achieved by routing a
+24 V signal via the feedback current path to a general digital input.
Fig. 6-19: Connection of a safety relay
45
6 horstCONTROL I/O
6.4.8.4
Safety Stop
The robot should be stopped safely as soon as the protected area of a safety laser scanner is entered. The first
example shows the connection of a laser scanner when
using the internal test signal. This is routed to the control
inputs of the laser scanner; its outputs are, in turn, routed
to the safety stop input of the main control.
Fig. 6-20: Safety Stop Laser Scanner with Internal
Test Signal
Some laser scanners are intended for the use of a separate
OSSD signal. In this case, only their outputs must be routed
to the safety stop input of the main control. In this configuration, the cross-circuit recognition must be deactivated in
horstFX and the filter time set greater than the test impulse
of the protection device (see Safety-critical Inputs/Outputs,
page 35).
Fig. 6-21: Safety Stop Laser Scanner with External
Test Signal
In both cases, the safety stop must be
acknowledged manually after exiting the
area. The adjacent example shows the options for connecting a safety stop with automatic continuation. Here, the laser scanner is
connected to a configurable safe input and
this input is assigned the Self-triggering
safety stop function.
Fig. 6-22: Self-triggering safety stop
46
6 horstCONTROL I/O
6.4.8.5
Connecting Emergency Stop for Several Devices
In a system, the robot should
be integrated in the emergency stop circuit of the other
devices so that there is no
need, in an emergency, to decide which emergency stop
button must be pressed. The
adjacent figure shows an example of the connection between two HORST robot systems. In each case, a configurable safe output is connected to a configurable safe
input.
6.4.8.6
Connection to a Superordinate Safety PLC
Robot 2
Robot 1
Fig. 6-23: Connecting emergency stop for several devices with each
other
The robot should be integrated in a system in
which a safety PLC controls and monitors the
safety functions. A configurable safe output is connected to a 2-channel input of the safety PLC here,
and a configurable safe input is connected to a 2channel output of the PLC.
Fig. 6-24: Superordinate safety PLC
6.4.8.7
Safe Deactivation of the Digital Outputs
General digital outputs DO01-16 should be deactivated in a safety-critical manner. To this
end, the bridge between X17.7 and X17.8 is removed and routed via the potential-free, safe
output SR5 together with the ground connection. A consumer connected to DO01 as shown
in this example is therefore safely deactivated.
Note that in this case all other consumers connected to the general digital outputs DO01-16
are also deactivated.
Fig. 6-25: Safe deactivation of the +24 V supply
and the digital outputs
47
6 horstCONTROL I/O
6.4.9
Wiring Examples of Digital Inputs/Outputs
The following examples show the use of the general digital inputs and outputs.
Fig. 6-26: Consumer at the digital output
Fig. 6-27: Button at the digital input
An inductive proximity switch in the configuration
as a PNP normally closed contact should be connected to a digital input.
Fig. 6-28: Inductive sensor at digital input
48
6 Tool I/O
6.5
Tool I/O
On support arm 3 of the robot, there are two interfaces (User 1, User 2), which supply current and control
signals for grippers and sensors that can be mounted at the tool interface of the support arm 3. Each of
these interfaces has two digital inputs/outputs as well as a +24 V power supply.
User 2
User 1
Fig. 6-29: Electrical connections for tools
Fig. 6-30: Tool I/O slot assignment
The interfaces are designed as 4-pin, A-coded M8 sockets (TE Connectivity T4071017041-001). As a
counter-piece, a plug connector with the following properties must be used:
M8 male, 4-ping, angled, A-coded.
The tool I/Os can be configured in horstFX as inputs or outputs ( Configuration of inputs/outputs → Special I/O menu). As standard, the two I/Os of the User 1 interface are configured as outputs and the two
I/Os of the User 2 interface are configured as inputs.
Configured as outputs, these act as Push-Pull switches and can be loaded with a maximum of 600 mA
each, if connected to the positive power supply, and a maximum of
200 mA each, if switched to ground. The maximum current-carrying capacity of all tool I/Os on
support arm 3, i.e. the four possible digital outputs and the +24 V power supply together, is
2.5 A.
Configured as inputs, these are compliant with IEC61131-2 Type 3.
A Functional diagram of this interface is provided in the Annex.
The parameters of the tool I/O are specified in the table on the next page.
49
6 Tool I/O
Parameter
min.
typ.
max.
Unit
Description
Voltage
-1.5
24
24.3
V
Input voltage
Switching threshold
5.5
6.8
V
Logical high–low
6.7
8
V
Logical low–high
2.6
mA
Inputs
HI – LO
Switching threshold
LO – HI
Current
tion
consump-
2.3
IEC 61131-2
Type
3
Type
Push-Pull, semiconductor
Outputs
Function
Voltage
24
V
Output voltage
Current HI_PP
0
0.6
A
Per output, logically high
Current LO_PP
0
0.2
A
Per output, logically low
240
mΩ
Logically high
150
µA
2.5
A
All 4 digital outputs and +24 V
kV
Contact
Internal resistance HI
Leakage current
120
-150
Total current
ESD strength
+/-7
Table 6-10: Characteristic values of tool inputs/outputs
50
6 Computer Interfaces
6.6
Computer Interfaces
In the horstCONTROL there is an integrated computer whose accessible interfaces are described in this subsection.
6.6.1
PROFINET (optional)
The horstCONTROL has an optional PROFINET communication interface (PROFINET IO, conformity class
C), through which it is possible to exchange data between a PLC and the robot. PROFINET (Process Field
Network) is a real-time capable industrial Ethernet protocol, which is used as the standard protocol in
automation. Using PROFINET communication, the robot can be controlled and monitored from the PLC.
HORST takes on the role of the client (Slave) and is controlled by the PLC (server or Master). As a result,
HORST is easy to integrate in an existing production line and can communicate with different peripheral
equipment. In addition to executing specific commands, there are also freely describable storage areas
in which Int, Float and Boolean data types can be exchanged.
The connection is made via a RJ45 modular connector and a category 5 network cable (CAT5) on the
front of the horstCONTROL (see subsection horstCONTROL (switch cabinet), page 23).
6.6.2
Ethernet
The Ethernet interface enables optional remote access and remote control of the robot. This is also used
for connection to horstCOSMOS, which enables e.g. program synchronization and the transmission of
telemetry data and error messages. For access to horstCOSMOS, the following are required:
−
connected network cable
−
connection to horstcosmos.com at port 443
−
TLS 1.2 and TLS 1.3 must not be blocked by the firewall
The RJ45 modular connector to the Ethernet port is on the rear side of the horstCONTROL. The characteristic values for the connection are as follows:
Transmission speed
6.6.3
min.
typ.
max.
Unit
10
-
1000
Mb/s
USB
To connect further input devices and data carriers, there are a total of four USB ports: two USB 3.1 ports
on the rear side of the horstCONTROL, and two USB 2.0 ports on the rear side of the horstPANEL. The
USB ports on the horstPANEL are only provided for input devices only. For data carriers, use the ports on
the horstCONTROL
51
7 Computer Interfaces
7
Commissioning
DANGER!
Danger resulting from incorrect commissioning
 Commissioning must be performed only by persons with technical and electrotechnical training who were also authorized by fruitcore robotics GmbH.
Before commissioning:
 Make sure that any transport equipment or transport securing devices have been removed.
 Make sure that the robot and any add-on parts are screwed on properly and safely.
 Ensure that there is sufficient room for the robot arm to move freely. There must be no obstacles or persons in the working area.
 Note that the range of the robot and thus the danger zone change with add-on parts and workpieces.
 If the robot is combined with other machinery in a system, make sure that the other machinery
cannot damage the robot.
 Make sure that the safety measures according to the risk assessment have been put in place
and configured to ensure that the commissioning personnel, operators, and bystanders are
protected.
 Familiarize yourself with the work environment of the robot system prior to commissioning.
 Ensure that suitable protection devices (e.g. separating protection device, light curtain, or
safety laser scanner) were installed. The protection devices must stop the robot’s movement
within the danger zone. Check the protection devices for proper function.
 In case of damage to the robot, horstCONTROL, or mechanical interface, as well as all parts of
the protection device, the robot must not be used.
 Protection devices (emergency stop, safety stop) must be connected only to safety-critical interfaces and must be designed to be redundant.
 Only operate the robot system in undamaged condition.
 Check the emergency stop and safety stop functions daily.
 Do not enter the danger zone of the robot during operation, and do not touch the robot.
 Make sure that the robot is grounded (power plug connected to PE protective conductor). A
suitable RCD (residual current operated device) must be installed.
 Before the power supply is switched on, it must be ensured that the connecting cable is connected between the horstCONTROL and the robot, and the power cable is connected to the
power supply.
52
7 Switching on the Robot System
7.1
Switching on the Robot System
 Switch the main switch on the horstCONTROL to ON.
 The software (horstFX) starts up on the horstPANEL.
 The main menu appears on the display.

Fig. 7-1: Main menu
 If a user role that is not authorized to remain logged in after a restart was logged
in when the software (horstFX) was last
used, the pop-up window for switching
the user role appears.
For information on the user roles, see the
User Roles subsection of the horstFX
software user manual.
Fig. 7-2: Switching user roles
 In the main menu, select connect to robot.
 Wait until the display shows “connection with robot established successful.”
In the next step, the robot must be initialized.
53
7 Initializing the Robot
7.2
Initializing the Robot
WARNING!
Danger of impact and crushing due to robot movement
The safety stop function is deactivated during the initialization.
 During initialization operation, close off the area around the robot and protect it against access by unauthorized persons. There must be no persons in the danger zone of the robot.
The initialization must be performed whenever the robot system is switched on after the power supply
was interrupted.
During the initialization, you should check the enabling switch for proper function by deliberately
letting it go and pressing it down every so often.
 In the main menu, select initialize robot. 
The Automatic initialization menu appears.

Fig. 7-3: Automatic initialization menu
The menu at the top right displays the initialization status of the six axes of the robot in the form of dots.
The axes that have not yet been initialized are shown as black dots. After the initialization, the color
changes to turquoise.
 Press and hold the enabling switch in the center position.
 Press and hold the Auto Init button.
 The automatic initialization of the axes is performed.
 If the initialization was successful, all six dots (initialization status) for the axes are
shown in turquoise.
54
7 Initializing the Robot
To perform the initialization, the axes (starting with axis 6) must carry out a movement one after the other.
If this is not possible, the axes must be moved manually. In this case, switch to the manual initialization
menu.
ATTENTION!
Keep an eye on the robot to prevent collisions.
 Select the Manuell (manual) button.  The manual initialization menu appears.

Fig. 7-4: Manual initialization menu
This allows the axes to be moved manually in the case that automatic initialization is not possible.
 Press and hold the enabling switch in the center position.
 Select the axes one after the other and move them slightly until successful initialization is displayed.
 If the initialization was successful, the dot (initialization status) for the respective axis is
shown in turquoise.
It may be necessary to open a gripper to perform the initialization. In this case, switch to the initialize
robot – outputs menu via the outputs button.

55
7 Initializing the Robot
Fig. 7-5: Initialize robot – outputs menu
Outputs can be switched manually here. For example, a gripper can be opened before the initialization
drive is continued.
 Switch the desired output via the corresponding changeover button.
The automatic/manual initialization of the axes was successful if all six dots (initialization status) for the
axes are shown in turquoise.
 The complete initialization button is activated.
 Press the complete initialization button. 
 The main menu is shown again.
 The robot is ready.
56
The initialization of the robot is completed.
8 Behavior in an Emergency
8
Operation
For information on how to operate the horstFX software, see the enclosed horstFX user manual
or go to www.horstcosmos.com
WARNING!
Danger due to the failure of the emergency stop and safety stop functions
 Check the emergency stop and safety stop functions daily.
8.1
Behavior in an Emergency
WARNING!
Danger of impact and crushing due to robot movement
The safety stop function is deactivated in teaching mode.
 While the robot is in teaching mode, close off the area around the robot, and protect it against
access by unauthorized persons. There must be no persons in the danger zone of the robot.
 While the robot is in teaching mode, secure the horstPANEL and horstCONTROL against operation by unauthorized persons.
WARNING!
The robot arm may be moved by applying external force only in emergencies.
Modules of the robot system may be damaged if the robot arm was moved manually in an
emergency. This may result in an uncontrolled start-up.
 Have the robot system checked by the customer service of fruitcore robotics GmbH before
recommissioning it.
1
 In an emergency, press the emergency
stop button (1).
 All movements of the robot are
braked until it comes to a standstill. The program is paused.
Fig. 8-1: horstPANEL
57
8 Operating Modes
 Rectify the danger situation.
 A pop-up window with a warning message stating that an emergency stop
was triggered appears on the display.
Fig. 8-2: Emergency stop warning message
Reset the emergency stop
 Check whether the danger has been rectified before resetting the emergency stop.
 Release the emergency stop button by
pulling it out.
 The confirm button is activated.
 Confirm the warning message on the
display.
 If the emergency stop was reset,
the program only starts up again
once it is continued manually.
Fig. 8-3: Emergency stop – confirmation
8.2
Operating Modes
The robot can be operated in three operating modes. Change the operating modes using the operating
mode selector switch on the horstCONTROL, which is designed as a key switch.
The following operating modes are provided for:
− Teaching mode T1 (manual operation with reduced speed)
− Teaching mode T2 (manual operation at high speed)
− Automatic mode
58
8 Operating Modes
1
Operating modes selector switch
2
Position for operating mode T1
3
Position for operating mode T2
4
Position for automatic mode
Fig. 8-4: Operating modes selector switch
8.2.1
Teaching mode
WARNING!
Danger of impact and crushing due to robot movement
The safety stop function is deactivated in teaching mode.
 While the robot is in teaching mode, close off the area around the robot, and protect it against
access by unauthorized persons. There must be no persons in the danger zone of the robot.
 While the robot is in teaching mode, secure the horstPANEL and horstCONTROL against operation by unauthorized persons. After teaching is completed, remove the key from the operating mode selector switch to prevent unauthorized switching of the operating mode.
 Switch on the robot system (see subsection 7.1, page 53).
The robot can only be moved manually in two-handed operation. To move the robot, the enabling
switch must always be kept pressed in the center position in operating modes T1 and T2. In
addition, the desired control element must be kept pressed on the display. As soon as one of the
two conditions is no longer fulfilled, the robot will brake to a standstill.
 If necessary, reinitialize the robot (see subsection 7.2, page 54).
If the power supply was interrupted previously, the robot must be reinitialized.
Switching to a different operating mode causes the robot to stop. A warning message appears
on the display. The message must be confirmed in order to proceed. The enabling switch must
be released during this time.
There are two teaching modes: T1 or T2.
59
8 Operating Modes
T1 – programming mode
The speed of the TCP (tool center point) is limited to 250 mm/s. The robot can be moved only with the
enabling switch.
Before programming waypoints, ensure that the system has reached operating temperature.
Thermal expansion in the robot system can result in position deviations.
 Switch the robot system on at least 60 minutes before the programming process and leave
the motors to warm up in energized mode (e.g. “Free Movement”).
T2 – program verification mode
The speed of the TCP (tool center point) can exceed 250 mm/s. The robot can be moved only with the
enabling switch.
 Switch the operating modes selector switch on the horstCONTROL to T1 or T2. Pull out the key
to prevent unauthorized persons from changing the operating mode.
 Confirm the change of operating mode.
 Create, edit, or execute a program (see user manual).
60
8 Operating Modes
8.2.2
Automatic Mode
Programs are executed automatically in automatic mode. The robot acts without the enabling switch and the
safety functions are active.
Danger!
Danger of impact and crushing due to robot movement
 Ensure that there are no persons within the protected area.
 Ensure that suitable protection devices (e.g. separating protection device, light curtain, or
safety laser scanner) are installed and are active.
Check the protection devices for proper function.
 Switch on the robot system (see subsection 7.1, page 53).
ATTENTION!
Danger of damage due to incorrect or missing configurations in the software.
 Ensure that the program to be executed has been programmed and tested correctly before
staring automatic mode.
ATTENTION!
Risk of collision due to program changes during automatic mode.
 Do not make any changes to the program during automatic mode.
 Ensure that no unauthorized persons have access to the horstPANEL.
 If necessary, reinitialize the robot (see subsection 7.2, page 54).
If the power supply was interrupted previously, the robot must be reinitialized.
Switching to a different operating mode causes the robot to stop. A warning message appears
on the display. The message must be confirmed in order to proceed. The enabling switch must
be released during this time.
61
8 Operating Modes
 Switch the operating modes selector switch on the horstCONTROL to automatic. Pull out the
key to prevent unauthorized persons from changing the operating mode.
 Confirm the change of operating mode; the enabling switch must be released to do this (see
horstFX user manual).
 Create, edit, or execute a program (see horstFX user manual).
62
8 Shutdown after End of Operation
8.3
Shutdown after End of Operation
At the end of operation, the robot system must be shut down.
 To cancel a running program, tap the
cancel program button (1).
 The robot is braked immediately.
1
Fig. 8-5: Cancel program execution
 Check whether the robot is in a safe position (e.g. there is no workpiece in the gripper).
If necessary, move the robot to a safe position manually via the free movement menu (see
horstFX user manual, section Free movement).
ATTENTION!
Before the robot system is switched off, it must be ensured that the computer for the software
(horstFX) that is integrated in the horstCONTROL is shut down properly.
 Navigate to the main menu. Tap on the Exit horstFX button there. A pop-up window with two
options appears. Select the option shut down system (1) and then confirm with the OK button
(2).
1
2
Fig. 8-6: Shutting down the computer for the software (horstFX)
63
8 Shutdown after End of Operation
 Alternatively, you can also shut down the computer for the software (horstFX) that is integrated
in the horstCONTROL as follows:
 Press the PC ON/OFF button (see subsection horstCONTROL (switch cabinet), page 23) on the
horstCONTROL. A pop-up window appears. In this pop-up window, press the Shut Down button
(1) to shut down the computer for the software (horstFX).
1
Fig. 8-7: Shutting down the computer for the software (horstFX)
 Switch the main switch on the horstCONTROL to ON.
 Secure the main switch with a lock.
64
9 Shutdown after End of Operation
9
Fault Rectification
If faults arise on the robot system, corresponding fault messages (system faults) are shown on the horstPANEL.
 Follow the instructions on the horstPANEL to rectify the cause of the fault.
 Confirm the fault message on the display once all causes of the fault have been removed.
 Call the fruitcore robotics GmbH service if you cannot remove the causes of the fault yourself.
In the case of software problems, switch off the robot system as described in subsection 8.3,
page 63 and switch it on again as described in subsection 7.1, page 53 .
If step losses occur due to overloading or blocking of the robot arm, the brakes are automatically activated. After 250 step losses or brake activations, the warranty of the brakes expires.
DANGER!
Danger due to faulty maintenance and brake failure
 Regularly check the load changes of the brakes via Settings & Info > Robot data > Robot
system data.
 After the permissible load changes of the brake have expired, contact the service department
of fruitcore robotics GmbH to have the brakes replaced professionally.
65
10 Cleaning
10 Cleaning and Maintenance
DANGER!
Danger of electric shock
 The connection and any work on the electrical equipment must be performed by electrotechnical specialist personnel only.
DANGER!
Danger resulting from incorrect maintenance
 Maintenance must be performed only by persons with technical and electrotechnical training
who were also authorized by fruitcore robotics GmbH.
WARNING!
Danger of impact and crushing due to unexpected robot movement
 Remove any workpieces from the gripper prior to cleaning or maintenance.
 Disconnect the robot system from the power grid and compressed-air supply prior to carrying
out cleaning or maintenance work.
 Disconnect any installed tools that are operated with compressed air from the compressed
air supply.
 Close off the danger zone and protect it against access by unauthorized persons.
 Set up warning signs to prevent the system from being started up while work is being performed. Secure the horstPANEL and horstCONTROL against operation by unauthorized persons.
WARNING!
Danger due to missing protection devices as well as defective/damaged modules or accessories.
 Assemble all protection devices after completing the work. Check all modules and accessories.
 After completing the maintenance work, perform a test run of the entire system, and check it
for proper functioning.
WARNING!
The robot arm must not be moved by applying external force.
Modules of the robot system may be damaged if the robot arm was moved manually in an
emergency. This may result in an uncontrolled start-up.
 Have the robot system checked by the customer service of fruitcore robotics GmbH before
recommissioning it.
Spare parts must correspond to the technical requirements specified by fruitcore robotics GmbH.
This is always guaranteed with original spare parts.
10.1 Cleaning
Depending on the ambient conditions of the robot system, the components become dirty. Clean the robot
regularly. Frequency of cleaning depends on the degree of soiling.
fruitcore robotics GmbH recommends cleaning the robot once a week.
66
10 Maintenance and Repair
The robot does not have to be disassembled for cleaning.
Wear protective clothing.
 Wear safety goggles, protective gloves, and a dust mask while cleaning.
 Use a vacuum cleaner or compressed air to remove dust, chips, and other particles from the
robot.
 Use a clean cloth to clean the horstCONTROL and horstPANEL.
ATTENTION!
Danger of machine damage
 Do not use compressed air to clean the horstCONTROL and horstPANEL.
 Do not use aggressive, flammable, or abrasive liquids/cleaning agents to clean the robot system.
 Avoid the ingress of liquids into parts of the system.
Environmental protection!
 Dispose of the waste and used cleaning cloths in an environmentally responsible way.
10.2 Maintenance and Repair
The operating personnel must check the robot system for external damage every day.
If there is a service contract with fruitcore robotics GmbH, care must be taken that the robot system data
is continuously sent to horstCOSMOS, see the horstFX user manual.
The drive belts must be checked by the fruitcore robotics GmbH service every year.
Only fruitcore robotics GmbH may carry out repairs on the robot system.
67
11 Maintenance and Repair
11 Storage
If the robot system is stored away for use at a later time or decommissioned, it must be protected with
suitable packaging.
The robot system must be stored in a dry, frost-protected place that is not exposed to rainfall or heavy
temperature fluctuations.
 Shut the robot down and disassemble it (see subsections Shutdown after End of Operation,
page 63 and Disassembly, page 69).
 Securely package the robot, horstPANEL, and horstCONTROL.
68
12 Disassembly
12 Disassembly and Disposal
12.1 Disassembly
 Disassemble or secure any add-on parts.
 Move the robot to transport position (see subsection Transport, page 18).
 Shut the robot down (see subsection Shutdown after End of Operation, page 63).
 Disconnect and remove any electrical and pneumatic lines from the power supply.
 Disconnect the connection cable between the robot and the horstCONTROL.
 Disassemble the robot.
 Prepare the robot system for transport (see subsection Transport, page 18).
12.2 Disposal
Danger of environmental damage.
All parts of the robot system must be disposed of in such a way that any damage to health or
the environment can be ruled out.
 Shut the robot down (see subsection Shutdown after End of Operation, page 63) and disassemble it.
 Dispose of all parts of the machine in such a way that any damage to health or the environment
can be ruled out. Note the materials used.
Materials Used
The following materials were used predominantly to build the robot system:
Material
Unit
Copper
Cable
Steel, aluminum
Modules of the robot
Plastic, rubber, PVC
Drive belts
Electronic scrap
horstCONTROL,
horstPANEL,
•
In the robot: Power electronics, mainboard,
motor driver, fan, rotary pulse generator
Table 12-1: Materials used
69
13 Technical Data
13 Annex
The Annex includes:
−
Technical Data
−
Information on Stopping Distances and Stopping Times
−
Information on Optional Accessories and Spare Parts
−
Information on Type Plates
−
Description of Connectors and Terminal Assignments
−
Functional Wiring Diagram of the Electrical Interfaces
13.1 Technical Data
Robot
Dimensions in as-delivered
condition (L x W x H)
602 mm x 200 mm x 450 mm
Robot weight
Approx. 30 kg
Nominal load according to VDI
2861-2
2 kg
The nominal load characterizes in terms of amount the
load that an industrial robot can handle as the vectorial
sum of tool load and payload without restriction of the
kinematic and geometric parameters specified for the
axes.
Measured at nominal distance Rn from the tool flange:
76.5 mm (eccentricity e: 38.3 mm; offset Z: 66.3 mm)
Permissible load capacity
Max. 3 kg
(After consultation with fruitcore robotics GmbH)
The permissible load capacity is reduced depending on
the position of the center of gravity of the load.
Maximum range
584 mm
(Note that the robot’s range changes when tools,
measuring devices, and workpieces are attached.)
70
Position repeatability
+/- 0.05 mm
Number of axes
6
Protection classification
IP54
Noise emission
< 70 dB(A)
Installation area (L x W)
382 mm x 200 mm
13 Technical Data
Axis data
H600
without
H600 fast
with
horstFX performance
of
horstFX performance
Axis
Range
movement
Speed
(independent of load)
1
+/- 173°
190°/s
370°/s
2
+115° / -64°
70°/s
140°/s
3
+41 / -176°
210°/s
420°/s
4
+/- 172°
610°/s
1220°/s
5
+/- 142°
470°/s
940°/s
6
+/- 300 °
640°/s
1280°/s
~ 1.4 m/s
~ 4.4 m/s
TCP Vmax
Axis
Acceleration
(independent of load)
Speed
(load capacity of 0 kg)
Acceleration
(at a load capacity of 0 kg)
1
370°/s²
740°/s²
2
100°/s²
200°/s²
3
810°/s²
1620°/s²
4
4410°/s²
8820°/s²
5
3140°/s²
6280°/s²
6
2750°/s²
5490°/s²
horstPANEL
Dimensions (L x W x H)
340 x 245 x 85 mm
Weight
2.4 kg
Display
13.3-inch touchscreen (Full HD monitor: 1920 x 1080)
Software
horstFX (graphical user interface)
Mount
Fixture for mounting on the wall, table, or cell
horstCONTROL
Dimensions (L x W x H)
460 x 315 x 175 mm
Weight
9 kg
Protection classification
IP20
Wiring of HORST
Cable between robot and horstCONTROL: 3.0 m
Wiring of the horstPANEL
DVI-D 24+1, 5.0 m
Power cable
5 m, CEE 7/4 / IEC-60320 C13, with pull-out protection
Power supply
115/230 VAC, 50 – 60 Hz, max 4.4 A (at 230 V)
71
13 Technical Data
horstCONTROL
Rated power draw
typ. 210 W (H600)
Protection
6.3 A (2x)
Communication
TCP/IP 100 Mbit Ethernet (web interface / http)
Safety-critical
Emergency stop, safety stop, enabling switch
interfaces
+4 safe inputs, +6 safe outputs (2 relays)
I/O connections on
horstCONTROL
20 inputs, +8 configurable
I/O connections for attachments
on support arm
2x 2 inputs/outputs
18 outputs, +8 configurable, +4 relay contacts
Ambient conditions
Ambient temperature
5 – 40 °C
Relative humidity
10 % – 75 %
The horstCONTROL must not be used in dusty or humid
environments that exceed protection classification IP54.
Conductive dust in particular must be avoided.
Height above sea level
72
Up to 1,000 m above sea level without power reduction
13 Stopping Distances and Stopping Times
13.2 Stopping Distances and Stopping Times
The stopping distance is the distance covered by the TCP (Tool Center Point) after the stop signal is
triggered and until a complete standstill is reached.
DANGER!
A speed update or load change can result in longer braking distances and unexpected collisions with people or other objects and machines.

Always adjust safety distances to the corresponding stopping distances.
ATTENTION!
Danger of damage to robot or property.
A collision can cause significant damage to the robot system or any surrounding objects.
The stopping time is the time that passes from the stop signal being triggered until the robot reaches a
complete standstill. The stopping distances and stopping times have been determined for the three main
axes Axis 1, Axis 2 and Axis 3.
The table shows the stopping distances and stopping times when triggered by an emergency stop signal
at speed 100 % with horstFX performance. Without horstFX performance the stopping time is the same
and the stopping distances are correspondingly shorter.
Average
stopping distance (°)
Average
stopping time (s)
Load 0 kg
Load 3 kg
Load 0 kg
Load 3 kg
Axis 1
106.3
63.9
0.49
0.48
Axis 2
32.7
14
0.48
0.49
Axis 3
94.1
44.8
0.48
0.49
Table 13-1: Stopping distances and times with horstFX performance
The braking time is a correcting variable defined by the control system. The stopping distance is therefore
independent of the respective load of the robot arm. The influence of speed on the stopping distance can
be seen in the figure below.
Fig. 13-1: Stopping distances of the main axes in degrees (°) with 0 kg
73
13 Stopping Distances and Stopping Times
Fig. 13-2: Stopping distances of the main axes in degrees (°) with 3 kg
The stopping distances and stopping times shown have been determined by trial and are
intended as guide values. The actual stopping distances and stopping times may differ depending
on operating mode, use case, and number of braking processes. It is therefore recommended
that stopping distances and stopping times be determined under real conditions in the respective
use case and the values checked at least once a year.
74
13 Optional Accessories
13.3 Optional Accessories
The following accessories can be purchased from fruitcore robotics GmbH.
Order no.
Component
Comment
On request
Tool flange
On request
Accessory flange plate
On request
Mobile Robot Base
On request
Safety laser scanner (270°)
Monitoring of the danger zone
On request
Mechanical stop, axis 2
Free of charge
On request
Mechanical stop, axis 3
Free of charge
Table 13-2: Optional accessories
Fig. 13-3: Mechanical stop, axis 2
Handling of Mechanical Stop, Axis 2:
1.
Set the stop in the software
2.
Loosen 1x cover screw
3.
Assemble the stop assembly, tightening torque 2 Nm
4.
Attach the stop screw to the stop with approx. 1 mm gap
75
13 Optional Accessories
Fig. 13-4: Mechanical stop, axis 3
Handling of Mechanical Stop, Axis 3:
1.
In the software, set the stop to 10° or 20°
2.
Loosen 2x cover screw
3.
Assemble the stop assembly, tightening torque 2 Nm
4.
Position the stop screw in accordance with the configured stop
Attaching External Energy Chains
Fig. 13-5: Attaching external energy chains
76
13 Spare Parts
13.4 Spare Parts
The following spare parts can be purchased from fruitcore robotics GmbH.
Order no.
Component
On request
Support arm 1
On request
Support arm 2
On request
Support arm 3
On request
horstCONTROL
On request
horstPANEL
On request
Cable - horstCONTROL / Robot
On request
Cardboard for packaging
Comment
Table 13-3: Spare Parts
77
13 Type Plates
13.5 Type Plates
The robot’s type plate is located on the
base of the rear side of the robot.
Fig. 13-6: Robot type plate
The horstCONTROL type plate is located
on its rear side.
Fig. 13-7: horstCONTROL type plate
The horstPANEL type plate is located on
its rear side.
Fig. 13-8: horstPANEL type plate
78
13 Overview of Connectors
13.6 Overview of Connectors
CONNECTOR
DESCRIPTION
X1
Digital inputs 1-8
X2
Digital inputs 9-16
X3
Digital inputs 17-20, Enable (enabling switch)
X4
Test signals A / B
X5
Safe inputs 4-7
X6
Emergency stop/safety stop
X7
Safe outputs 1-4
X8
Safe outputs 5-6 (pot.free)
X9
Digital outputs 1-8
X10
Digital outputs 9-16
X11
Digital outputs 17-18, +24 V
X12
+24 V
X13
+24 V
X14
Ground
X15
Ground
X16
Ground
X17
RS-485, bridge +24 V
Table 13-4 Digital I/O horstCONTROL connectors
79
13 Terminal Assignment
13.7 Terminal Assignment
Terminal
Assignment
I/O
Safe
Description.
X1.1 … X1.8
DI01 … DI08
I
General digital inputs 1-8
X2.1 … X2.8
DI09 … DI16
I
General digital inputs 9-16
X3.1 … X3.4
DI17 … DI18
I
General digital inputs 17-20
X3.5
ENA
A
Test signal for enabling switch, channel A
X3.6
ENA
I
Enabling switch input (SI3A), channel A
Standard: Bridge to X3.5
X3.7
ENB
A
Test signal for enabling switch, channel B
X3.8
ENB
I
Enabling switch input (SI3B), channel B
Standard: Bridge to X3.7
X4.1 … X4.4
TA
A
Test signal A
X4.5 … X4.8
TB
A
Test signal B
X5.1
SI4A
I
Configurable, safe input 4, Channel A
X5.2
SI4B
I
Configurable, safe input 4, Channel B
X5.3
SI5A
I
Configurable, safe input 5, Channel A
X5.4
SI5B
I
Configurable, safe input 5, Channel B
X5.5
SI6A
I
Configurable, safe input 6, Channel A
X5.6
SI6B
I
Configurable, safe input 7, Channel B
X5.7
SI7A
I
Configurable, safe input 8, Channel A
X5.8
SI7B
I
Configurable, safe input 8, Channel B
X6.1
EIA out
A
Test signal for emergency stop, channel A
X6.2
EIA in
I
Emergency stop input (SI1A), channel A
Standard: Bridge to X6.1
X6.3
EIB out
A
Test signal for emergency stop, channel B
X6.4
EIB in
I
Emergency stop input (SI1B), channel B
Standard: Bridge to X6.3
X6.5
TA
A
Test signal for safety stop, channel A
X6.6
SSIA
I
Safety stop input (SI2A), channel A
Standard: Bridge to X6.5
X6.7
TB
A
Test signal for safety stop, channel B
X6.8
SSIB
I
Safety stop input (SI2B), channel B
Standard: Bridge to X6.7
80
X7.1
SO1A
A
Configurable, safe output 1, Channel A
X7.2
SO1B
A
Configurable, safe output 1, Channel B
13 Terminal Assignment
Terminal
Assignment
I/O
Safe
Description
X7.3
SO2A
A
Configurable, safe output 2, Channel A
X7.4
SO2B
A
Configurable, safe output 2, Channel B
X7.5
SO3A
A
Configurable, safe output 3, Channel A
X7.6
SO3B
A
Configurable, safe output 3, Channel B
X7.7
SO4A
A
Configurable, safe output 4, Channel A
X7.8
SO4B
A
Configurable, secure output 4, Channel B
X8.1
SR5A1
A
Conf. safe output 5, potential-free contact A1
X8.2
SR5A2
A
Conf. safe output 5, potential-free contact A2
X8.3
SR5B1
A
Conf. safe output 5, potential-free contact B1
X8.4
SR5B2
A
Conf. safe output 5, potential-free contact B2
X8.5
SR6A1
A
Conf. safe output 6, potential-free contact A1
X8.6
SR6A2
A
Conf. safe output 6, potential-free contact A2
X8.7
SR6B1
A
Conf. safe output 6, potential-free contact B1
X8.8
SR6B2
A
Conf. safe output 6, potential-free contact B2
X9.1 … X9.8
DO01 … DO08
A
General digital outputs 1-8
X10.1 … X10.8
DO09 … DO16
A
General digital outputs 9-16
X11.1 … X11.2
DO17 … DO18
A
General digital outputs 17-18
X11.3 … X11.8
+24V
A
Power supply +24 V
X12.1 … X12.8
+24V
A
Power supply +24 V
X13.1 … X13.8
+24V
A
Power supply +24 V
X14.1 … X14.8
GND
A
Ground
X15.1 … X15.8
GND
A
Ground
X16.1 … X16.8
GND
A
Ground
X17.1
RS485_A
I/O
RS-485 add-on port #1, Signal A
X17.2
RS485_B
I/O
RS-485 add-on port #1, Signal B
X17.3
GND
A
Ground
X17.4
RS485_A
I/O
RS-485 add-on port #2, Signal A
X17.5
RS485_B
I/O
RS-485 add-on port #2, Signal B
X17.6
GND
A
Ground
X17.7
+24V_out
A
Output power supply DO01-16
X17.8
+24V_in
I
Input power supply DO01-16
Standard: Bridge to X17.7
Table 13-5: Terminal assignment of digital I/O horstCONTROL
Legend:
Safe I/O Unsafe
I/O Configurable I/O
81
13 Functional Wiring Diagrams of the Electrical Interfaces
13.8 Functional Wiring Diagrams of the Electrical Interfaces
13.8.1 horstCONTROL I/O
Safe input
General digital input
General digital output (High-Side)
82
Safe Output
Potential-free output
13 Functional Wiring Diagrams of the Electrical Interfaces
General digital output (Push-Pull)
13.8.2 Tool I/O
Digital input/output
83
14 Functional Wiring Diagrams of the Electrical Interfaces
14 Glossary
Stop category 0
Stopping is achieved by an immediate interruption in the power supply to the drive components. This
uncontrolled stopping can cause the robot to deviate from its programmed track. For more information
on this, see EN ISO 13850 or DIN EN 60204-1.
Stop category 1
Stopping is achieved through active braking, as the energy supply to the drive components is initially
maintained. Only after a successful stop is the power supply disconnected. This is a controlled stop, during which the robot does not exit is programmed track. For more information on this, see EN ISO 13850
or DIN EN 60204-1.
Stop category 2
Stopping is achieved through active braking (controlled stopping), and after the stop, the energy supply
to the drive components is maintained. The safe control system monitors the stop. For more information
on this, see DIN EN 60204-1.
Performance Level
The Performance Level (PL) describes the capacity of safety-related parts of a control system to execute
safety-critical functions under predictable conditions. The required Performance Level is also used to
achieve the required risk minimization for individual safety functions. Therefore, the Performance Level
of safety-critical parts of a control system must be at least as high as the required Performance Level.
The Performance Level “d” is the second highest reliability classification. For more information on this,
see DIN EN 13849-1.
84
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