fruitcore robotics HORST600 Assembly Instructions Manual
PDF
เอกสาร
โฆษณา
โฆษณา
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 ">
/
ดาวน์โหลด
ขอแจ้งให้ทราบ คุณสามารถดูเอกสารได้ที่นี่ แต่ที่สำคัญที่สุดคือ AI ของเราได้อ่านแล้ว สามารถอธิบายสิ่งที่ซับซ้อนด้วยคำศัพท์ง่ายๆ ตอบคำถามของคุณในทุกภาษา และช่วยคุณนำทางเอกสารที่ยาวหรือซับซ้อนที่สุดได้อย่างรวดเร็ว
ลิงก์สาธารณะได้รับการอัปเดตแล้ว
ลิงก์สาธารณะไปยังแชทของคุณได้รับการอัปเดตแล้ว You may view and manage your chat links after registration here.
ลิงก์สาธารณะของเอกสาร
โฆษณา
