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HANWHA HCR-5 USER MANUAL

Table of Contents
Table of Contents
COLLABORATIVE ROBOT SYSTEM
Easy setting
Flexible rearrangement
Safe collaboration
SYSTEM COMPONENTS
BASIC SYSTEM CONFIGURATION
OVERVIEW OF ROBOT ARMS
OVERVIEW OF ROBOT CONTROLLER
Front
Bottom
OVERVIEW OF TEACHING PENDANT
Front
Rear
AXIAL COORDINATES AND OPERATIONAL RANGE
Robot's Working Range
MAXIMUM LOAD CAPACITY FOR THE TOOL
SAFETY MARKS IN THE USER MANUAL
GENERAL SAFETY CAUTIONS
INTENDED USE
POTENTIAL DANGERS
LIMITATION OF LIABILITY
TRANSPORTATION
EMERGENCY STOP
Using emergency stop
Canceling emergency stop
SAFETY FENCE
LIMITS OF SPEED AND ROTATIONAL ANGLES
OPERATING ROBOTS WITHOUT DRIVING POWER
SAFETY CONTROLLER
RISK ASSESSMENT
INSTALLATION LOCATIONS
INSTALLATION TYPES
FIXING ROBOTS
CONNECTING TOOLS TO ROBOTS
CONNECTING CABLES
Connecting the teaching pendant to the robot controller
Connecting the robot arm to the robot controller
Connecting the power supply to the robot controller
FIXING THE CONTROLLER BOX
OVERVIEW OF CONTROLLER I/O
COMMON SPEC FOR DIGITAL I/O
CONFIGURING THE SAFETY INPUT
Initial safety configuration
Connecting the emergency stop button
Safety protection stop and restart
CONFIGURING THE GENERAL DIGITAL I/O
Load control with digital outputs
Digital input control using buttons
Communicating with other equipment or PLC
CONFIGURING THE GENERAL ANALOG I/O
Analog output
Analog input
TURNING ON THE ROBOT CONTROLLER
TURNING ON THE TEACHING PENDANT
MENU OVERVIEW
Expanding menu
Robot Operation
Programming
Monitoring
Robot Setting
Safety Setting
Device Setting
Management
SW Configuration
Message
Manual Move
3D Preview Screen
Screen display setting button
Robot task control button
MANUAL MOVE SCREEN
VIRTUAL KEYPAD
Text keypad
Number keypad
Expression keypad
MANAGING ROBOTS
Registering robots
Modifying the robot name
Registering Force Torque Sensor
MANAGING USERS
Adding users and setting authorities
Menu available to each authority
Login/Logout
Logging in
Logging out
CHECKING STATUS
Checking Robot Status
Checking errors
Checking the software version
SETTING THE ROBOT INSTALLATION ANGLES
SETTING TCP
Creating a new TCP profile
Calculating the TCP position
Setting the TCP orientation
Changing the TCP profile name
Editing the TCP profile
Deleting the TCP profile
Setting Inputs/Outputs
Types of digital I/O
Editing the digital inputs settings
Editing the digital outputs settings
Types of analog I/O
Editing the analog I/O setting
COORDINATES
Registering points
Registering line coordinates
Registering plane coordinates
SETTING GLOBAL VARIABLES
I/O BIT OPERATION
Add/Delete
I/O bit operation settings
LIMITING ROBOT MOVEMENT
Default settings
Manual setting method
SETTING SAFETY BOUNDARIES
Adding safety boundary planes
Viewing safety boundary planes
Applying safety boundaries
Changing the name of safety boundaries
Deleting safety boundary settings
SETTING TOOL BOUNDARIES
Adding Tool Safety Boundary Surfaces
Setting Tool Safety Boundary Surfaces
Applying Tool Safety Boundary Surfaces
SETTING REDUNDANT I/O
SETTING SAFEGUARD I/O
EXCEEDING SAFETY LIMIT OF JOINTS
HOW TO USE COMMANDS
Selecting a flowchart
Type of commands
Additional Commands
Entering commands
Check Icon Status
Changing command names
Deleting commands
Searching Commands
Skipping Commands
Tree
SETTING VARIABLES
Adding variables
Modifying variables
Deleting variables
Variable Monitoring
EDITING PROGRAMS
Overview of edit menu
Example of program editing
Undo Function
ANAGING AROGRAM
Saving a program
Making a new program
Loading a program
Deleting a program
Export as script
Export Program File
USING TEMPLATES
Saving as a template
Loading a template
Deleting a template
APPLYING PROGRAMS
MOVE COMMAND
Selecting a movement method
Radius of Linear
Don't stop at this point
Blending
Advanced
Setting the coordinates for movement
Displaying as groups
IF COMMAND
LOOP COMMAND
SWITCH COMMAND
WAIT COMMAND
SET COMMAND
FOLDER
Change Programed Icons into Folder
Create New Folder
MESSAGE
Output format
Message operation
Message format
Select message
PATTERN COMMAND
Pattern types
Setting the pattern coordinates
Setting repeat counts
Advanced commands for patterns
Setting pattern points
USING A SUB PROGRAM
Making a sub program
Saving and loading a sub program
Entering a sub program
CONVEYOR
Conveyor Setting
Conveyor Start Options
Setting Conveyor Command
VISION COMMAND
Setting basic options
Setting the movement speed
Setting the movement location
THREAD
Thread Tab
Thread Creation
Event Tab
SCRIPT
Script Viewer
PATH COMMAND
Recording Paths
Turning ON/OFF the robot
Monitoring
Checking and setting the robot operation data
Operating the robot
Locking Screen
MONITORING THE ROBOT
Monitoring the robot positions
Checking the robot status
Monitoring Inputs/Outputs
Monitoring controller inputs/outputs
Monitoring tool inputs/outputs
UTILIZATION
CONFIGURING MODBUS TCP
Registering Devices
Editing/copying the device settings
Registering I/O
Viewing the communication status
Viewing and setting the I/O values
Editing I/O settings
Deleting I/O
USING A VISION SYSTEM
ADDING AND SETTING VISION EQUIPMENT
Adding a vision equipment
Setting a vision equipment
SETTING VISION WORKSPACE
Adding Vision Workspace
Understanding rotation offsets
GENERAL SETTING
NETWORK SETTING
SHUTTING DOWN THE OPERATION SOFTWARE
TURNING OFF CONTROLLERS
INSPECTION ITEMS AND PERIODS
CHECKING THE ROBOT ARM
Inspection period
Checking and cleaning the robot arm
CHECKING THE CONTROLLER
Checking and cleaning the controller
Cleaning and replacing the filter
VIEWING AND MANAGING LOGS
Deleting Logs
Exporting Logs
MANAGING THE ROBOT SYSTEM CONFIGURATION
Packaging posture
Factory reset
Use Default Program
Exporting the configurations
Importing the configurations
SOFTWARE UPDATE
Cautions during update
Updating software
Warranty
Warranty period
Limitation of Liability
Safety
MD(Machinery Directive)
LVD(Low Voltage Directive)
EMC (Electro Magnetic Compatibility)
Cleanroom-Body
Cleanroom-Controller
Other ManualsLib Projects
 HCR-5
Collaborative Robot

User Manual

A ug. 2019

V 2.001
 Preface

Before installing the product, please read this manual fully and make sure you follow
the instructions in it.

The content of the manual is maintained latest as of the date when it is written. The
product information is subject to change without prior notice to users.

If you are uncertain about any requirements, recommendations or safety procedures

described in the manual, please, consult with Hanwha Precision Machinery Co.

Users are responsible for any damages caused by their misuse neglecting these
instructions below.

Note  Some of illustrations in the manual intends to help users in

understanding the system concepts and installation issues. The actual
product may differ from the manual.
 Please keep this manual in a safe place for future reference.
 Voltage : 100~240VAC, 50/60Hz(1kW)(It should be connected to the
neutral cable which is connected with grounding line with one phase of
the 3 phase cables.)
 Status of load installation : Load is not exceeding the payload of Robot.
 Please check the grounding line connection in plant and operating cell.
(It can be refer to section 3.3 to check the location of grounding line.)
- Any plants and cells with the inappropriate grounding line may have
the negative influence such as noise on the communication line between
robot and system.
- Especially, if robot is installed with the equipment requiring large
current such as heater, motor, separate additional grounding line is
required.

3
 Copyrights

The copyrights and intellectual property rights of all the content and diagrams in the
manual belong to Hanwha Precision Machinery Co.

Thus, illegal use, duplication, distribution or dissemination of the manual without prior
written approval by Hanwha Precision Machinery Co. is strictly prohibited and such an
activity is an infringement of the intellectual property rights of Hanwha Precision
Machinery Co.

Users are responsible for any damages caused by their misuse or modification of the
patent rights for the equipment.

The information provided by the manual is deemed trustworthy by Hanwha Precision

Machinery Co. Hanwha Precision Machinery Co. is not responsible for any situations
arising due to inaccuracy or typo in the content of the manual.

The information provided in the manual is subject to change without prior notice and
for more details about revisions made in the manual, please visit the homepage of
Hanwha Precision Machinery Co.([Link]

© 2019 Hanwha Precision Machinery Co., Ltd. All rights reserved

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 Table of Contents

Table of Contents
PREFACE ................................................................................................................................................................... 3

COPYRIGHTS ............................................................................................................................................................. 4

CHAPTER 1 PRODUCT OVERVIEW .................................................................................................................... 15

1.1 COLLABORATIVE ROBOT SYSTEM......................................................................................................15

Easy setting ................................................................................................................................... 15
Flexible rearrangement .................................................................................................................15
Safe collaboration .........................................................................................................................16
1.2 SYSTEM COMPONENTS .....................................................................................................................17
1.3 BASIC SYSTEM CONFIGURATION .......................................................................................................18
1.4 OVERVIEW OF ROBOT ARMS.............................................................................................................19
1.5 OVERVIEW OF ROBOT CONTROLLER ................................................................................................21
Front ............................................................................................................................................. 21
Bottom .......................................................................................................................................... 22
1.6 OVERVIEW OF TEACHING PENDANT..................................................................................................23
Front ............................................................................................................................................. 23
Rear .............................................................................................................................................. 24
1.7 AXIAL COORDINATES AND OPERATIONAL RANGE ............................................................................25
1.8 ROBOT'S WORKING RANGE ..............................................................................................................27
1.9 MAXIMUM LOAD CAPACITY FOR THE TOOL.......................................................................................28

CHAPTER 2 SAFETY .......................................................................................................................................... 29

2.1 SAFETY MARKS IN THE USER MANUAL..............................................................................................29

2.2 GENERAL SAFETY CAUTIONS ............................................................................................................30
2.3 INTENDED USE .................................................................................................................................. 31
2.4 POTENTIAL DANGERS .......................................................................................................................32
2.5 LIMITATION OF LIABILITY .................................................................................................................32
2.6 TRANSPORTATION ............................................................................................................................33
2.7 EMERGENCY STOP ............................................................................................................................34
Using emergency stop ...................................................................................................................34
Canceling emergency stop ............................................................................................................34
2.8 SAFETY FENCE .................................................................................................................................. 35
2.9 LIMITS OF SPEED AND ROTATIONAL ANGLES ....................................................................................35
2.10 OPERATING ROBOTS WITHOUT DRIVING POWER ..............................................................................35
2.11 SAFETY CONTROLLER .......................................................................................................................35

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2.12 RISK ASSESSMENT ............................................................................................................................. 35

CHAPTER 3 INSTALLATION ............................................................................................................................... 37

3.1 INSTALLATION LOCATIONS ...............................................................................................................37

3.2 INSTALLATION TYPES ........................................................................................................................38
3.3 FIXING ROBOTS ................................................................................................................................ 40
3.4 CONNECTING TOOLS TO ROBOTS .....................................................................................................41
3.5 CONNECTING CABLES.......................................................................................................................42
Connecting the teaching pendant to the robot controller .............................................................42
Connecting the robot arm to the robot controller ........................................................................42
Connecting the power supply to the robot controller ...................................................................43
3.6 FIXING THE CONTROLLER BOX ........................................................................................................44
3.7 OVERVIEW OF CONTROLLER I/O ......................................................................................................45
3.8 COMMON SPEC FOR DIGITAL I/O .....................................................................................................45
3.9 CONFIGURING THE SAFETY INPUT .....................................................................................................48
Initial safety configuration ............................................................................................................49
Connecting the emergency stop button ........................................................................................50
Safety protection stop and restart .................................................................................................50
3.10 CONFIGURING THE GENERAL DIGITAL I/O .......................................................................................51
Load control with digital outputs .................................................................................................51
Digital input control using buttons ...............................................................................................52
Communicating with other equipment or PLC ............................................................................52
3.11 CONFIGURING THE GENERAL ANALOG I/O ......................................................................................53
Analog output............................................................................................................................... 54
Analog input ................................................................................................................................. 54

CHAPTER 4 GETTING STARTED ......................................................................................................................... 55

4.1 TURNING ON THE ROBOT CONTROLLER...........................................................................................55

4.2 TURNING ON THE TEACHING PENDANT ............................................................................................56

CHAPTER 5 SOFTWARE OVERVIEW .................................................................................................................. 57

5.1 MENU OVERVIEW ............................................................................................................................. 57

Expanding menu...........................................................................................................................57
Robot Operation ..........................................................................................................................57
Programming ................................................................................................................................ 57
Monitoring ................................................................................................................................... 58
Robot Setting ................................................................................................................................ 58
Safety Setting ................................................................................................................................ 58
Device Setting ............................................................................................................................... 58

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Management ................................................................................................................................. 58
SW Configuration .........................................................................................................................58
Message ........................................................................................................................................ 58
Manual Move ............................................................................................................................... 58
5.2 3D PREVIEW SCREEN ........................................................................................................................59
Screen display setting button ........................................................................................................59
Robot task control button ............................................................................................................60
5.3 MANUAL MOVE SCREEN ..................................................................................................................61
5.4 VIRTUAL KEYPAD.............................................................................................................................. 63
Text keypad .................................................................................................................................. 63
Number keypad ............................................................................................................................64
Expression keypad ........................................................................................................................64

CHAPTER 6 REGISTERING ROBOTS AND USERS ................................................................................................ 66

6.1 MANAGING ROBOTS.........................................................................................................................66

Registering robots .........................................................................................................................67
Modifying the robot name............................................................................................................67
Registering Force Torque Sensor ..................................................................................................67
6.2 MANAGING USERS ............................................................................................................................69
Adding users and setting authorities .............................................................................................69
Menu available to each authority .................................................................................................70
6.3 LOGIN/LOGOUT ............................................................................................................................... 71
Logging in ..................................................................................................................................... 71
Logging out .................................................................................................................................. 72
6.4 CHECKING STATUS............................................................................................................................72
Checking Robot Status ................................................................................................................72
Checking errors ............................................................................................................................72
Checking the software version ....................................................................................................73

CHAPTER 7 SETTING ROBOTS ........................................................................................................................... 74

7.1 SETTING THE ROBOT INSTALLATION ANGLES....................................................................................74

7.2 SETTING TCP ................................................................................................................................... 75
Creating a new TCP profile ..........................................................................................................76
Calculating the TCP position ........................................................................................................78
Setting the TCP orientation ..........................................................................................................81
Changing the TCP profile name ...................................................................................................83
Editing the TCP profile .................................................................................................................83
Deleting the TCP profile ...............................................................................................................84

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7.3 SETTING INPUTS/OUTPUTS ................................................................................................................85

Types of digital I/O ......................................................................................................................85
Editing the digital inputs settings ..................................................................................................86
Editing the digital outputs settings ................................................................................................86
Types of analog I/O .....................................................................................................................87
Editing the analog I/O setting.......................................................................................................88
7.4 COORDINATES .................................................................................................................................. 89
Registering points .........................................................................................................................89
Registering line coordinates ..........................................................................................................90
Registering plane coordinates .......................................................................................................90
7.5 SETTING GLOBAL VARIABLES ............................................................................................................91
7.6 I/O BIT OPERATION .........................................................................................................................92
Add/Delete ................................................................................................................................... 92
I/O bit operation settings .............................................................................................................92

CHAPTER 8 SAFETY SETTINGS........................................................................................................................... 93

8.1 LIMITING ROBOT MOVEMENT ..........................................................................................................93

Default settings ............................................................................................................................. 94
Manual setting method .................................................................................................................94
8.2 SETTING SAFETY BOUNDARIES ..........................................................................................................97
Adding safety boundary planes.....................................................................................................97
Viewing safety boundary planes ...................................................................................................98
Applying safety boundaries...........................................................................................................99
Changing the name of safety boundaries .................................................................................... 100
Deleting safety boundary settings ............................................................................................... 100
8.3 SETTING TOOL BOUNDARIES........................................................................................................... 102
Adding Tool Safety Boundary Surfaces ...................................................................................... 102
Setting Tool Safety Boundary Surfaces ....................................................................................... 103
Applying Tool Safety Boundary Surfaces ................................................................................... 103
8.4 SETTING REDUNDANT I/O .............................................................................................................. 104
8.5 SETTING SAFEGUARD I/O................................................................................................................ 106
8.6 EXCEEDING SAFETY LIMIT OF JOINTS .............................................................................................. 107

CHAPTER 9 PROGRAMMING ...........................................................................................................................108

9.1 HOW TO USE COMMANDS .............................................................................................................. 108

Selecting a flowchart................................................................................................................... 108
Type of commands ..................................................................................................................... 109
Additional Commands ................................................................................................................ 110

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Entering commands .................................................................................................................... 111

Check Icon Status ....................................................................................................................... 111
Changing command names ........................................................................................................ 111
Deleting commands .................................................................................................................... 112
Searching Commands ................................................................................................................. 112
Skipping Commands................................................................................................................... 112
Tree ............................................................................................................................................ 113
9.2 SETTING VARIABLES ........................................................................................................................ 114
Adding variables ......................................................................................................................... 114
Modifying variables .................................................................................................................... 115
Deleting variables ....................................................................................................................... 115
Variable Monitoring ................................................................................................................... 115
9.3 EDITING PROGRAMS........................................................................................................................ 116
Overview of edit menu ............................................................................................................... 116
Example of program editing ....................................................................................................... 117
Undo Function ............................................................................................................................ 118
9.4 MANAGING A PROGRAM ................................................................................................................ 119
Saving a program........................................................................................................................ 119
Making a new program .............................................................................................................. 119
Loading a program ..................................................................................................................... 120
Deleting a program ..................................................................................................................... 120
Export as script .......................................................................................................................... 121
Export Program File ................................................................................................................... 121
9.5 USING TEMPLATES .......................................................................................................................... 122
Saving as a template ................................................................................................................... 122
Loading a template ..................................................................................................................... 123
Deleting a template ..................................................................................................................... 123
9.6 APPLYING PROGRAMS ..................................................................................................................... 124
9.7 MOVE COMMAND .......................................................................................................................... 125
Selecting a movement method .................................................................................................... 125
Radius of Linear ......................................................................................................................... 127
Don’t stop at this point .............................................................................................................. 127
Blending ...................................................................................................................................... 127
Advanced .................................................................................................................................... 129
Setting the coordinates for movement ........................................................................................ 129
Displaying as groups ................................................................................................................... 130
9.8 IF COMMAND................................................................................................................................. 131

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Table of Contents

9.9 LOOP COMMAND ......................................................................................................................... 132

9.10 SWITCH COMMAND ..................................................................................................................... 133
9.11 WAIT COMMAND .......................................................................................................................... 134
9.12 SET COMMAND ............................................................................................................................. 135
9.13 FOLDER .......................................................................................................................................... 136
Change Programed Icons into Folder ......................................................................................... 136
Create New Folder ..................................................................................................................... 136
9.14 MESSAGE ........................................................................................................................................ 137
Output format ............................................................................................................................ 137
Message operation ...................................................................................................................... 137
Message format .......................................................................................................................... 138
Select message ............................................................................................................................. 138
9.15 PATTERN COMMAND .................................................................................................................. 139
Pattern types ............................................................................................................................... 139
Setting the pattern coordinates ................................................................................................... 140
Setting repeat counts................................................................................................................... 140
Advanced commands for patterns .............................................................................................. 141
Setting pattern points .................................................................................................................. 142
9.16 USING A SUB PROGRAM .................................................................................................................. 143
Making a sub program ............................................................................................................... 143
Saving and loading a sub program ............................................................................................. 144
Entering a sub program .............................................................................................................. 144
9.17 CONVEYOR .................................................................................................................................... 146
Conveyor Setting ....................................................................................................................... 146
Conveyor Start Options ............................................................................................................. 147
Setting Conveyor Command ..................................................................................................... 147
9.18 VISION COMMAND ....................................................................................................................... 148
Setting basic options ................................................................................................................... 148
Setting the movement speed ........................................................................................................ 148
Setting the movement location.................................................................................................... 149
9.19 THREAD ......................................................................................................................................... 150
Thread Tab ................................................................................................................................. 150
Thread Creation ......................................................................................................................... 150
Event Tab ................................................................................................................................... 151
9.20 SCRIPT ............................................................................................................................................ 152
Script Viewer .............................................................................................................................. 152
9.21 PATH COMMAND ........................................................................................................................... 153

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Recording Paths .......................................................................................................................... 153

CHAPTER 10 STARTING THE ROBOT ..................................................................................................................155

Turning ON/OFF the robot ....................................................................................................... 156

Monitoring ................................................................................................................................. 156
Checking and setting the robot operation data .......................................................................... 157
Operating the robot .................................................................................................................... 157
Locking Screen ........................................................................................................................... 159

CHAPTER 11 MONITORING ...............................................................................................................................160

11.1 MONITORING THE ROBOT .............................................................................................................. 160

Monitoring the robot positions .................................................................................................. 160
Checking the robot status ........................................................................................................... 161
11.2 MONITORING INPUTS/OUTPUTS ..................................................................................................... 161
Monitoring controller inputs/outputs ......................................................................................... 162
Monitoring tool inputs/outputs .................................................................................................. 163
11.3 UTILIZATION .................................................................................................................................. 164

CHAPTER 12 DEVICE SETTINGS ..........................................................................................................................165

12.1 CONFIGURING MODBUS TCP ....................................................................................................... 165

Registering Devices ..................................................................................................................... 166
Editing/copying the device settings ............................................................................................. 167
Registering I/O ........................................................................................................................... 168
Viewing the communication status ............................................................................................. 170
Viewing and setting the I/O values ............................................................................................. 170
Editing I/O settings ..................................................................................................................... 171
Deleting I/O................................................................................................................................ 171
12.2 USING A VISION SYSTEM ................................................................................................................. 172
12.3 ADDING AND SETTING VISION EQUIPMENT ...................................................................................... 173
Adding a vision equipment ......................................................................................................... 173
Setting a vision equipment .......................................................................................................... 173
12.4 SETTING VISION WORKSPACE ......................................................................................................... 175
Adding Vision Workspace .......................................................................................................... 175
Understanding rotation offsets.................................................................................................... 176

CHAPTER 13 ENVIRONMENT SETTING ..............................................................................................................178

13.1 GENERAL SETTING.......................................................................................................................... 178

13.2 NETWORK SETTING ........................................................................................................................ 179

CHAPTER 14 TURNING OFF THE SYSTEM ...........................................................................................................180

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14.1 SHUTTING DOWN THE OPERATION SOFTWARE ............................................................................... 180

14.2 TURNING OFF CONTROLLERS ......................................................................................................... 180

CHAPTER 15 MAINTENANCE .............................................................................................................................181

15.1 INSPECTION ITEMS AND PERIODS .................................................................................................... 181

15.2 CHECKING THE ROBOT ARM .......................................................................................................... 182
Inspection period ........................................................................................................................ 182
Checking and cleaning the robot arm......................................................................................... 182
15.3 CHECKING THE CONTROLLER ........................................................................................................ 182
Inspection period ........................................................................................................................ 182
Checking and cleaning the controller ......................................................................................... 182
Cleaning and replacing the filter ................................................................................................. 183
15.4 VIEWING AND MANAGING LOGS .................................................................................................... 184
Deleting Logs .............................................................................................................................. 184
Exporting Logs ........................................................................................................................... 184
15.5 MANAGING THE ROBOT SYSTEM CONFIGURATION ......................................................................... 185
Packaging posture ....................................................................................................................... 185
Factory reset ............................................................................................................................... 186
Use Default Program .................................................................................................................. 186
Exporting the configurations ...................................................................................................... 186
Importing the configurations ...................................................................................................... 187
15.6 SOFTWARE UPDATE......................................................................................................................... 189
Cautions during update .............................................................................................................. 189
Updating software ...................................................................................................................... 189

APPENDIX A WARRANTY ..................................................................................................................................191

Warranty .................................................................................................................................... 191

Warranty period ......................................................................................................................... 191
Limitation of Liability ................................................................................................................. 191

APPENDIX B CERTIFICATION .............................................................................................................................192

Safety ......................................................................................................................................... 192

MD(Machinery Directive) .......................................................................................................... 194
LVD(Low Voltage Directive)...................................................................................................... 195
EMC (Electro Magnetic Compatibility) ..................................................................................... 196
Cleanroom-Body ....................................................................................................................... 197
Cleanroom-Controller ............................................................................................................... 198

APPENDIX C DIMENSIONS FOR INSTALLATION .................................................................................................199

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APPENDIX D TOOL FLANGE CROSS SECTION......................................................................................................200

APPENDIX E PORT PIN MAP..............................................................................................................................201

APPENDIX F SYSTEM SPECIFICATIONS ..............................................................................................................202

APPENDIX G STOPPING TIME AND DISTANCE ...................................................................................................203

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 Chapter 1 Product Overview

Chapter 1 Product Overview

1.1 Collaborative Robot System

Hanwha Precision Machinery's collaborative robot, HCR-5 is a user-friendly robot

that provides an automation environment where it can safely collaborate next to
humans in various fields.

Easy setting
By using the direct teaching feature and the intuitive S/W GUI, users can easily
configure and control the robot.

 While holding the robot gently, users can implement desired movements, so that the robot
can detect and memorize movements.
 Users can preview the robot movement in a real time 3D and use the icon based intuitive
GUI for easy operation.
 As the installation method is simple, even if users are not robot engineers, they can easily
configure the initial setting and program the robot.

Flexible rearrangement
Users can easily rearrange the robot, so that it can be applied to various processes easily
and quickly.

 Since users can operate the robot in small space, it is possible to rearrange the robot
without changing the layout of the manufacturing line.
 The robot is light weighted and easy to move, and its simple programming environment
allows the robot to be easily adapted to high-mix, low-volume production.

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Chapter 1 Product Overview

Safe collaboration
Using the various safety features, users can safely work next to the robot without using
additional safety tools or devices.

 The robot is automatically stopped when it detects an impact, so as long as the working
range of the robot and the user are guaranteed, it can be installed anywhere for safe use.

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 Chapter 1 Product Overview

1.2 System Components

The following is a list of system components.

Robot arm Teaching pendant

Robot controller Teaching pendant fixing bracket

12 pin tool cable User manual

17
Chapter 1 Product Overview

The following list indicates the quantity of each component.

Robot Robot arm 1 EA

Robot controller 1 EA
Controller and teaching
Teaching pendant 1 EA
pendant
Teaching pendant fixing bracket 1 EA

12 pin tool cable 1 EA

Others
User manual 1 EA

1.3 Basic System Configuration

Power Command &

supply & monitoring
network
Teaching
Robot controller pendant
Robot arm

 Robot arm: It is an industrial collaborative robot that can be used to convey objects or
assemble parts, and it can be used by attaching various tools such as grippers.
 Robot controller: Can control the robot arm's various movements according to the
program prepared by the user. It can be connected with various devices and equipment
through its various I/O ports.
 Teaching pendant(TP): It is a device used for system operation. It can teach the robot a
specific position or control and configure the robot in many ways.

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 Chapter 1 Product Overview

1.4 Overview of Robot Arms

Parts and joints

➊ Tool Flange ➎ Lower Arm ➒ J2 Shoulder

➋ J6 Wrist3 ➏ Elbow ➓ J1

➌ J5 Wrist2 ➐ J3 Base

➍ J4 Wrist1 ➑ Upper Arm

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Chapter 1 Product Overview

Functions

No. Name Description

It is the area in the robot where a tool is mounted.

 Tool flange For more details, refer to 3.4 Connecting Tools to
Robots.
It is the I/O port used to control a tool.
 Tool I/O For more details about specifications, refer to
Appendix E Port Pin Map .
It is the Ethernet based port used for communication

 EtherCAT with a tool. For more details about specifications, refer

to Appendix E Port Pin Map .

Indicates the status of robot.

 Green: Operation mode

 LED  Blue: Direct teaching mode
 Red: Emergency stop mode
 Pink: Exceeding joint range limits in direct teaching
It is the area in the robot that is fixed to the ground or
 Robot base
wall.

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 Chapter 1 Product Overview

1.5 Overview of Robot Controller

Front

No. Name

 Handle

 Air exhaust hole (exhaust hole filter)

 Air intake hole (intake hole filter)

 Controller cover locking screw

 Teaching pendant fixing hook

 Controller fixing bracket

 Teaching pendant fixing bracket

21
Chapter 1 Product Overview

Bottom

No. Name

 Robot connector

 Teaching pendant connector

 Power button

 AC power socket

22
 Chapter 1 Product Overview

1.6 Overview of Teaching Pendant

Front

No. Name Description

Turn on/off the power of the teaching pendant.

 Power button For more details, refer to 4.2 Turning on the Teaching
Pendant.

Emergency stop Press it to stop the robot.

 button For more details, refer to 2.7 Emergency Stop .

A resistive touch screen that detects a touch even if user

 Touch screen
wears a glove.

USB 2.0 port that can be used by plugging in a USB

 USB port
memory, keyboard, mouse, etc.1

1
Some devices may not be compatible with the teaching pendant.

23
Chapter 1 Product Overview

Rear

No. Name Description

Users can insert their hands and lift the teaching

 Handle pendant for use. Users can turn the handle and insert
their hand in the desired direction.

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 Chapter 1 Product Overview

1.7 Axial Coordinates and Operational Range

It consists of a total of six axes and an axis of each joint has the following coordinates
and operational ranges. The direction of arrow indicates the (+) rotational angle and
the opposite direction of arrow indicates the (-) rotational angle.

Operational axis Operational range

J1 axis -360° < rz1 ≤ +360°

J2 axis -360° < rz2 ≤ +360°

J3 axis -165° < rz3 ≤ +165°

J4 axis -360° < rz4 ≤ +360°

J5 axis -360° < rz5 ≤ +360°

J6 axis -360° < rz6 ≤ +360°

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Chapter 1 Product Overview

Note The J3 axis has a limited operational range due to its unique structure.

When the J3 axis is at +165° When the J3 axis is at -165°

26
 Chapter 1 Product Overview

1.8 Robot's Working Range

The radius of rotation for the robot when its arm is fully stretched is 915 mm. The
radius of 176.5 mm from the center axis of the base is the area where the robot arm
cannot reach due to its structure.

 A: Working range where the robot arm cannot reach

 B: Working range where the robot arm can reach

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Chapter 1 Product Overview

1.9 Maximum load capacity for the tool

The load capacity of the robot arm may vary depending on the distance between the
tool flange and the payload's center of gravity. The load capacity per distance is as
follows:

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 Chapter 2 Safety

Chapter 2 Safety

2.1 Safety Marks in the User Manual

The user manual contains the following safety marks.

Danger
If a user does not obey the safety mark, then it can cause a severe accident including
death or serious injury of a user.

Warning
If a user does not obey the safety mark, then it can cause an accident including serious
injury of a user.

Caution
If a user does not obey the safety mark, then it can cause a damage to the product or
injury of a user.

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Chapter 2 Safety

2.2 General Safety Cautions

Danger
User needs to install the robot and the electrical equipment by complying with the
instructions given in Chapter 3 Installation.

Warning
 Robot application system manufacturers and robot users should be familiar with this manual
and complete the robot operation training.
 Make sure sufficient space is available so the robot arm can move freely.
 When using the robot, a user should not wear loose clothes or accessories. If you have long
hairs, then tie it in the back so that it does not stuck in the robot's joints.
 Do not ever use a damaged robot.
 If a fatal error occurs in the software, then immediately stop it and contact the product
supplier.
 Check if values such as the robot installation angle, tool settings and safety settings are
correctly inputted.
 Do not connect the safety device to a general I/O. Safety device is used only for safety related
I/O.
 When using the teaching pendant, pay close attention to the robot's movements.
 When the robot is operating, do not enter the working range of the robot or touch the robot.
 Do not modify the robot on your own. If a user causes a problem by modifying or
remodeling the product on their own, then Hanwha Precision Machinery will not be
responsible for it in any sort of way.
 The robot and the controller can generate heat after long hours of use. Do not touch the
robot after long hours of use. If you need to touch the robot, then power off the controller
and cool down the robot first.
 When the robot collides with an external object, a significant level of kinetic energy is
generated, which is proportional to the speed and the payload. (Kinetic energy = 1/2 × mass
× speed2)
 Regarding the robot installation, make sure to use a proper configuration for installation. If
robot mounting, tool weight, tool's center of gravity, tool length, safety configuration, etc.
are not correctly entered, the direct teaching or collision detection function may not work
properly.
 You should use the direct teaching function in a safe environment. DO NOT use it if there is
a sharp part or cause of jamming in a tool or surrounding installations.

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 Chapter 2 Safety

 Correctly enter tool related information (the length, weight, center of gravity of the tool, etc.)
before using the direct teaching function. If you enter information different from the actual
specification of the tool, you may experience malfunction when using the direct teaching
function.
 If a joint is operated at the speed beyond a certain limit when using the direct teaching
function, it may make an emergency stop for the safety of operators.

Caution
 It is recommended that you test all the functions separately before using the machine or other
robot that can damage the robot. If other machine or robot is damaged by programming
errors or robot failures, Hanwha Precision Machinery will not be responsible for it.
 Do not expose the robot to a strong magnetic field. Your robot can be damaged.

2.3 Intended Use

This robot may be used for transport, and assembly of objects with tools. However, use
it only under the environment specified by its specifications.

Since the safety function is built in, the collaborative work is possible without physical
protective fence. However, for the final system applied with robot, the risk assessment
should be conducted on the whole system before use.

The system integrator or the end user who implements the robot applied final system
shall take the responsibilities as follows:
(These are examples and are not limited to them.)

 Use in potentially explosive environment.

 Medical applications and human life related applications
 Use in human and animal transportation
 Use without the risk assessment
 Use in places where the performance of the safety function is not sufficient
 Use beyond its performance and environmental specifications

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Chapter 2 Safety

2.4 Potential Dangers

If the risk assessment, conducted by the final system manufacturer who applied the
robot, concludes that it is not possible to fully reduce the risk only with the built-in
safety function, additional protective measures should be established.

Consider potential dangers as follows:

 Injuries that may occur if the human body part such as finger is caught in the robot joints
(confinement).
 Injuries caused by sharp edges or corners of tools (stab or penetration)
 Injuries caused by objects around the robot (stab, penetration, or falling)
 Injuries that may occur when working on toxic or hazardous materials (skin damage or
dyspnea)
 Injuries caused by collisions with the robot (bruise or fracture)
 Injuries caused by loosely coupled parts.
 Injuries caused by objects separated or fallen from the tool.

Note Potential dangers that may occur vary depending on the final system.

2.5 Limitation of Liability

This user manual does not cover all of the peripherals affecting the safety. A system
installer must comply with the safety requirements according to the safety rules and
laws of the country where the robot is installed.

The robot is configured as the final system interconnected with peripherals. This user
manual covers neither the design, installation, operation of the final system nor all of the
peripherals including the safety device.

The final system which applied the robot shall be designed and installed according to
the safety requirements in compliance with laws and regulations of the country where it
is installed.

The system integrator or the end user who implements the robot applied final system
shall take the responsibilities as follows:
(These are examples and are not limited to them.)

 Risk assessment on the final system

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 Chapter 2 Safety

 Addition of safety devices according to the risk assessment results

 To check whether the system is correctly designed, set up and installed
 Definition on how to use the system
 Providing information on operation and safety as well as contact information
 Provision of technical documents including the user manual

Complying with the safety items in the user manual does not mean that all possible risks
are prevented.

2.6 Transportation

The weight of the robot arm is 20.8 kg and that of the controller box is 20.2 kg. A
minimum of two people is required for moving it safely.

Carry the controller box by holding the handle at the top.

Warning
During transportation, avoid damages caused by falling accidents. The warranty
does not cover any damage caused during transportation.

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Chapter 2 Safety

2.7 Emergency Stop

You can press the emergency stop button to immediately stop the robot in case of
emergency. The emergency stop button is basically located in the teaching pendant and
you can stop the robot by connecting another emergency stop button to the robot
controller.

Caution
In the event of a collision or an emergency stop while driving over the speed of
120°/sec, check the zeroing of the robot joint and calibrate it if needed. After that,
check if the movement path of the tool set in the operating program is correct.
Contact the manufacturer or the service representative if you need the zeroing
adjustment.

Using emergency stop

You can press the emergency stop button in the teaching pendant to immediately stop
the robot.

Canceling emergency stop

Turn the emergency stop button clockwise to cancel emergency stop.

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 Chapter 2 Safety

2.8 Safety Fence

Unlike other kinds of industrial robots that adopt physical fences, virtual fences are
implemented to make sure that the TCP does not reach out of certain limits. For more
details, refer to 8.2 Setting Safety Boundaries .

2.9 Limits of Speed and Rotational Angles

By limiting the rotational angle and speed of each joint, you can secure your safety. For
more details, refer to 8.1 Limiting Robot Movement .

2.10 Operating Robots without Driving Power

In case of emergency, when the robot is not driven by power, an adult can move each
axis with their own force.

Caution
If you use excessive force to move the axis when the robot is not being driven by
power, it can overload the driving unit. The manufacturer is not responsible for the
failure caused by excessive force.

2.11 Safety Controller

The safety controller for HCR-5 complies with the ISO13849 Cat3. PLd class.

2.12 Risk Assessment

The risk assessment is one of the important factors when configuring a robot configured
system. The degree of safety regarding robot installation varies depending on the way of

35
Chapter 2 Safety

integrating it into the entire system, so it is not possible to perform the risk assessment
with the robot alone.

The person who configures the robot included system to perform the risk assessment of
the robot should install and operate it according to instructions of ISO 12100 and
ISO10218-2 standards. For further information, refer to the Technical Specification
ISO/TS15066.

You must perform the risk assessment right after the robot is installed. The main
objectives of the risk assessment are to set up safety configuration suitable for the
surrounding environment and robot settings and to find out the need for additional
emergency stop buttons and protective measures.

It is possible to configure functions related to safety of the collaborative robot from the
Safety Configuration Setting menu. Available functions are as follows:

 Joint Rotation Limit: You can limit the angle of each joint.
 Joint Speed Limit: You can limit the speed of each joint.
 TCP Speed Limit: You can limit the max speed for the TCP's linear movement.
 Force Limit: You can limit the maximum force that stops the robot when it detects a
collision with a surrounding object.
 Safety Boundary Limit: You can build a virtual fence within the robot working area to
prevent robot arms or tools from moving beyond the boundary for the safety of users.
 Redundant I/O Setting: You can set up redundancy to an I/O terminal to input/output
important safety-related information.

If dangers are not sufficiently reduced or removed through the safety related functions
above, add more protective measures to remove them. The manufacturer is not
responsible for accidents caused by noncompliance with relevant requirements of
international standards and local laws and regulations in relation to installation or due
to not performing review on those requirements during the risk assessment as above.

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 Chapter 3 Installation

Chapter 3 Installation

The installer should install and operate the robot according to instructions of ISO
12100 and ISO10218-2 standards and comply with relevant requirements of
international standards such as ISO/TS 15066 and local laws and regulations.

The manufacturer is not responsible for accidents caused by noncompliance with

relevant requirements of international standards and local laws and regulations or due
to not performing review on the risk assessment as mentioned in Section 2.12.

3.1 Installation Locations

It is recommended to install the system in a place which meets conditions as follows:

 A building with earthquake-resistant design

 A place without water leaks
 A place free of flammability or explosives
 A place that maintains the constant temperature and humidity
 A place with little dusts

Caution
If the system is not installed in a recommended place, the performance and the life
span of the robot may be reduced.

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Chapter 3 Installation

3.2 Installation Types

You can install the robot arm on ceiling, wall or floor as follows.

Example of installation on floor

Example of installation on wall

Example of installation on ceiling

38
 Chapter 3 Installation

You can also install it on a moving dolly or fixed post.

Example of installation on a moving dolly Example of installation on a fixed

post

Warning
If you install the robot on a moving dolly, you must make sure the moving dolly is
fixed to the ground when operating the robot.

Note The moving dolly or fixed post is not included in the product package.

After installing the robot, you must configure the robot installation information
depending on each type of installation. For more details, refer to 7.1 Setting the Robot
Installation Angles .

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Chapter 3 Installation

3.3 Fixing Robots

You can install the robot arm on the ceiling, wall or floor by using 4 pieces of M8 bolts
not shorter than 15mm and it is recommended to fasten those bolts with 45 Nm torque.
If the strength or levelness of the installation ground is not sufficient for supporting the
robot arm, then you can use a fixing base for installation. In this case, if you want to
install the robot arm in an accurate location, then you can use two Φ8 location
determination pins to determine the location. In addition, to prevent electrostatic
charges, you must connect the grounding line using a piece of M4 x 10 mm bolt.

Connect the grounding line

Warning
 When fixing the robot, securely fasten the bolts to prevent them from getting
loose.
 Install it on a flat ground that can with withstand the robot's weight and the
weight that is generated when the robot is operating.
 Check that the installation plane of the robot arm is completely in contact with its
base plane.

Note  The base fixing bolt is not included in the product package.
 For more details about specifications of the robot base, refer to
Appendix C Dimensions for Installation.

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 Chapter 3 Installation

3.4 Connecting Tools to Robots

1. Using four sets of M6 bolts, fix a tool to the tool flange.

Note  Tools and fixing M6 bolts are not included in the product package.
 The tool combination method varies from tool to tool. For more
detailed methods, refer to the user manual provided by the tool
maker.
 For more details about specifications of tool flange, refer to Appendix
D Tool Flange Cross Section.

2. After fixing the tool, connect the necessary cables to the tool I/O or the EtherCAT
port.
 For the tool I/O, you can select one from the analog input (current (0 – 20 mA),
voltage (0 – 10 V)), the digital input (4Ch) and the digital output (4Ch, 0, 12, 24
Vdc).

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Chapter 3 Installation

Note  For more details about specifications of the pin maps for the tool I/O
and the EtherCAT, refer to Appendix E Port Pin Map.

3.5 Connecting Cables

Connecting the teaching pendant to the robot controller

After connecting the teaching pendant cable, by using fixing bolts for the connector,
securely fasten it, so that the cable does not slip out. Be careful of pin being bended
while connecting.

Connecting the robot arm to the robot controller

After connecting the robot arm cable to the robot controller, hook a fixing latch, so that
the cable does not slip out.

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 Chapter 3 Installation

Connecting the power supply to the robot controller

Connect the power cable approved in your country to the power terminal. Robot
controller's power terminal accepts standard IEC plugs.

The minimum requirements for power supply are ground, main fuses and circuit
breakers, and they should be prepared by the person who prepares for installation.

The following electrical specifications are applicable to power supplies.

Input power 100 ~ 240 VAC

External power supply fuse 8 ~ 16 A (100 ~ 240 V)

Input frequency 47 ~ 63 Hz

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Chapter 3 Installation

Caution
While the robot is on, do not remove the robot connector, the power connector or
the teaching pendant connector. When connecting teaching pendant to controller,
pay attention to the pin of the connector.

3.6 Fixing the Controller Box

The controller box can be fixed to the ground by using the fixing bracket at the bottom.
Fix it with M14 bolts not shorter than 45 mm in combination with flat washers.

Note Bolts or screws fixing the controller box are not included in the product
package.

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 Chapter 3 Installation

3.7 Overview of Controller I/O

If you want to connect other external equipment to your controller, then you must first
connect it to the I/O inside the controller box. The controller I/O is very flexible, so it
can be connected to various equipment such as relays, PLC, and emergency stop
buttons.

The following electrical interface layout exists for the area inside the controller box.

3.8 Common Spec for Digital I/O

The section defines the electrical specifications of the following 24V digital I/O for the
controller box.

 Safety Input: 4 EA
 Flexible I/O: Input 8 EA, Output 8 EA
 General I/O (Digital I/O): Input 8 EA, Output 8 EA

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Chapter 3 Installation

By implementing the terminal block called IO Power (J8), you can supply power to the
digital I/O from an internal 24V power supply or external power supply. The left two
blocks are composed of internal 24V(INT_24V), GND and the right two blocks are
composed of external 24V(EXT_24V), GND. They can supply power from the outside
to the digital I/O.

Basically, internal 24V power is supplied for use. The basic power supply configuration
is as follows.

INV Internal 24 V I/O power supply Current limit: 2 A

ING Internal 24 V I/O GND Typ. DC 24 V

EXV External 24 V I/O power supply Min. DC 23 V

External 24 V I/O GND Max. DC 26 V

EXG

If the digital I/O power supply provided from the inside of the controller is not
sufficient, then you can connect an additional power supply externally. If an
internal/external power supply is used, then the current limit of 2A is applied.

If the digital I/O requires more current, then you can connect an external power supply
as follows.

Note If the current is over the upper limit, then the digital I/O fuse can blow off.
If the fuse is blown off, you need to replace it.

You can configure the terminal block called as Power Switch (J9) to use it as an external
power supply switch.

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 Chapter 3 Installation

SW+ Push Button Input

SW+ Push Button Input

SW- GND

SW- GND

The following electrical specifications apply to the internal or external power supply.

Terminal Parameter Minimum Format Maximum Unit

Internal 24V power supply
Voltage 23 24 25 V
INT – ING
Current 0 - 2 A
External 24V requirements
Voltage 20 24 29 V
EXV – EXG
Current 0 - 2 A

The digital I/O is manufactured by complying with the IEC 61131-2 standard. The
following electrical specifications apply.

Terminal Parameter Minimum Format Maximum Unit

Digital output
FOx / DOx Current 0 - 0.2 A
FOx / DOx Voltage drop 0 - 0.5 V
FOx / DOx Leakage current 0 - 0.1 mA
FOx / DOx Functions - PNP - Format
FOx / DOx IEC 61131-2 - 1A - Format

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Chapter 3 Installation

Terminal Parameter Minimum Format Maximum Unit

Digital input
EIx/SIx/FIx/DIx Voltage - V
EIx/SIx/FIx/DIx OFF area - V
EIx/SIx/FIx/DIx ON area - V
EIx/SIx/FIx/DIx Current (11-30V) - mV
EIx/SIx/FIx/DIx Functions - PNP - Format
EIx/SIx/FIx/DIx IEC 61131-2 - 3 - Format

3.9 Configuring the Safety Input

Since a single signal loss should not lead to a loss of the safety function, all the I/O's
related to the safety should be duplexed.

Safety Input should always comply with the common specs of the digital I/O.

When you install the safety device or equipment, you should comply with the
instructions from Chapter 2 Safety and Chapter 3 Installation.

Safety inputs include emergency stop and safety protection stop. Emergency stop input
is for emergency stopping of the robot and safety protection stop input is for protection
of all the safety classes. Their functions are different from each other in this sense.

Emergency Stop Safety protection stop

Robot stops the movement Example Example

Run the program Stop Pause

Robot power Off On

Initialization Manual Auto or manual

Frequency of use Low Mid

Re-initialization required Break release only No

Stop category (IEC 60204) 1 2

Performance level (ISO

PLd PLd
13849-1)

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 Chapter 3 Installation

Using the Flexible I/O, you can set the Safety I/O additionally. For example, you can
use the emergency stop output. In addition, you can configure the Flexible I/O for the
safety function in the GUI.

Danger
Do not connect safety signals to normal PLCs. Only safety PLCs must be connected
to safety signals. If you do not comply with the warning, then the safety stop function
may fail, causing severe injury or even death. The safety signal and the general I/O
signal should be separated from each other.

Warning
 All the safety class I/O's are duplexed. By separating the channels, you should
make sure the safety function is not initiated by a signal failure.
 Before installing the robot, you must check the safety functions. In addition, the
function should be checked for defects periodically.

Initial safety configuration

The safety settings of the robot at the factory are as follows.

- Operation software: Unassigned

- Robot controller(Emergency connector): As shown below

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Chapter 3 Installation

Connecting the emergency stop button

It is recommended that you connect one or more emergency stop button. The
emergency stop button is composed as follows.

Safety protection stop and restart

As an example of basic safety protection device, basically, when the door opens, you
can press the door switch to stop the robot. You can configure the function as follows.

If you cannot close the door after a worker passed through it, then you can use the
following features. As another way to resume robot operation, you can use the safety
mat or the safety class laser scanner.

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 Chapter 3 Installation

3.10 Configuring the General Digital I/O

If not used as a safety function, then you can use the Flexible I/O as a general purpose
digital I/O.

The general digital I/O should comply with the common specifications of digital I/O.

The general digital I/O can be used to configure relays or PLC systems. In this
configuration, if the program is not running, the output is maintained low at all times.

Load control with digital outputs

You can control loads with digital outputs. You can configure it as follows.

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Chapter 3 Installation

Digital input control using buttons

You can connect a simple button to a digital input. You can configure it as follows.

Communicating with other equipment or PLC

The digital I/O can be configured to communicate with other equipment if a common
GND is established and if the equipment uses PNP technology. You can configure it as
follows.

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 Chapter 3 Installation

3.11 Configuring the General Analog I/O

It can be used to set or measure voltage (0-10V) or current (4-20mA) between two
equipment.

For high reliability, it is recommended that you use the following method.
 Use the analog ground closes to the I/O.
 Equipment and control box should share the same ground. Analog I/O is not insulated in
the control box.
 Use the cable that is shielded or twist paired. Connect it to the ground shield of the power
(J12) terminal.
 The current signal is not sensitive to noise, so simply use an equipment operating in current
mode.

The input mode can be set in the GUI. The following electrical specifications apply to
the I/O.

Terminal Parameter Minimum Format Maximum Unit

Current mode input
AIx - AG Current 4 - 20 mA
AIx - AG Resistance - 20 - Ohm
AIx - AG Resolution - 12 - Beat
Voltage mode input
AIx - AG Current 0 - 10 V
AIx - AG Resistance - 12 - Kohm
AIx - AG Resolution - 12 - Beat
Current mode output
AOx - AG Current 4 - 20 mA
AOx - AG Resistance 0 - 10 V
AOx - AG Resolution - 12 - Beat
Voltage mode output
AOx - AG Voltage 0 - 10 V
AOx - AG Current -20 - 20 mA
AOx - AG Resistance - 1 - ohm
AOx - AG Resolution - 12 - Beat

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Chapter 3 Installation

Analog output
You can use analog outputs as speed control inputs to the conveyor belt. You can
configure it as follows.

Analog input
You can use analog sensor outputs as analog inputs. You can configure it as follows.

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 Chapter 4 Getting Started

Chapter 4 Getting Started

4.1 Turning on the Robot Controller

Turn on the power switch at the bottom of the controller. If you turn on the power
switch for the controller, power will be supplied to the controller.

55
Chapter 4 Getting Started

4.2 Turning on the Teaching Pendant

Turn on the power button at the left top of the teaching pendant.

Caution
 Do not turn on the teaching pendant with USB devices connected. It may cause
problems with starting the system. Connect it after the system is booted
completely.
 Do not unnecessarily touch the screen while booting the system. It may cause
problems with starting the system.

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 Chapter 5 Software Overview

Chapter 5 Software Overview

5.1 Menu Overview

Expanding menu
Press the expanding menu button at the left top of the screen to expand the
menu. You can check the name of each menu and if a sub menu exists,
then you can select it as well.

Robot Operation
You can configure basic operation / control (start, pause) of your robot.
For more details, refer to Chapter 10 Starting the Robot.

Programming
You can configure the robot's movements.
For more details, refer to Chapter 9 Programming.

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Chapter 5 Software Overview

Monitoring
You can check the real time condition of the robot arm.
For more details, refer to Chapter 11 Monitoring .

Robot Setting
You can configure the installation information before operating the
robot. For more details, refer to Chapter 7 Setting Robots.

Safety Setting
You can configure the safety items before operating the robot safely.
For more details, refer to Chapter 8 Safety Settings.

Device Setting
You can configure an external equipment that will be linked to the robot.
For more details, refer to Chapter 12 Linking with External Equipment.

Management
You can register a robot or user and manage logs, etc.
For more details, refer to Chapter 6 Registering Robots and Users, 16.4
Viewing and Managing Logs & 16.5 Managing the Robot System
Configuration .

SW Configuration
You can configure the operation software environment.
For more details, refer to Chapter 13 Environment Setting.

Message
You can select whether or not to display the message window that shows
messages that have been set while the robot program is running.

Manual Move
You can control the robot manually.
For more details, refer to 5.3 Manual Move Scree.

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 Chapter 5 Software Overview

5.2 3D Preview Screen

The system provides a screen where you can preview the robot's movement or
coordinates in 3D. You can drag on the screen in the desired direction to change the
screen perspectives.

Screen display setting button

You can configure the information displayed on the preview screen and the screen
layout.

Basic setting button

Hide or unhide the TCP coordinates.

Initialize the size of the preview screen.

Decrease the size of the preview screen. (Level 10)

Increase the size of the preview screen. (Level 10)

Unhide the additional setting button.

Hide the additional setting button.

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Chapter 5 Software Overview

Additional setting button

Hide or unhide the point of the movement path for the tool currently
programmed.
Hide or unhide the location/direction of the TCP currently set for the
robot.

Hide or unhide the movement path currently programmed.

Hide or unhide the safety borders currently set for the robot.

Note Depending on the purpose of the menu, some buttons are not available in
the preview screen.

Robot task control button

You can preview the programmed robot tasks.

Start the program from the beginning or at the selected task.

When you press the Start button, it changes to the Pause button.

Pause the running program.

When you press the Pause button, it changes to the Start button again.

Execute the unit command that are currently selected.

When done, it is automatically selected with the next command.

Terminate an ongoing task.

Note Depending on the purpose of the menu, some buttons are not available in
the preview screen.

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5.3 Manual Move Screen

On this screen, you can control the robot's positions. By using jog control or direct
teaching, you can control the robot's position.

Press the Manual Move button in the main menu.

 Coordinate System : Selects Coordinate System for manual move. (Base, View, TCP)
 Tool Position: Displays the coordinates of TCP.
 Joint Position: Displays the angle of the joints. You can modify it by entering a specific
angle.
 Rotation: Rotates the TCP by using jog buttons.
 Direct Teaching: If you manually adjust the robotic arm as you press this button, the
system detects any changes in the joint position. When the Manual Control of Robot screen
is accessed, the payload of current TCP is displayed for 3 seconds. If the joint range is
exceeded during direct teaching, the LED color of tool flange will turn pink.
 Home: Shifts the robot to its initial position. It works only if the button is pressed.
 Speed: Adjusts the movement speed of the robotic arm when you control the robotic arm
manually.
 Inching: You can set the robot to move in increments of a certain distance or angle.
- Default: 5mm, 5degree
- Moving Range : 0.01~10 mm

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- Rotating Range : 0.01~ 10degree

Note Depending on the purpose of the menu that uses the manual robot control
function, the screen layout may differ accordingly.

If you press the coordinate value on the screen, the screen will be changed as follows,
and then you can enter the coordinates and the joint angles on your own.

 Press the Input reset button to reset the coordinates and joints’ angles you input to the
current coordinate of the robot.
 Press the Move button to move the robot arm to the preset position according to the Move
type.

Warning
When controlling the robot manually, check that there is no obstacle or person
around the robot before operating it.

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Caution
 When using the direct teaching function, check that the center of gravity of the
TCP payload is correctly entered. Entering an incorrect value may cause
malfunction.
 If you drive a joint beyond a certain speed while using the direct teaching
function, it may make a noise and make an emergency stop for the safety of
operators.

5.4 Virtual Keypad

The operation software accepts touch based inputs, so you can use a virtual keypad on
the screen. Depending on the input types, there are three types of virtual keypads as
follows.

Text keypad
You can enter or edit simple English texts or special characters. You can use the Shift
key to toggle between uppercase/lowercase.

 If you want to display your inputted text, press the Accept key.

 If you want to delete the entire inputted text string, press the button.

 If you want to close the keypad, then press the button at the right top.

Note The Accept key is deactivated and cannot be used if there is no inputted
text string.

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Number keypad
You can enter or edit simple numbers.

 If you want to display your inputted numbers, press the Enter key.

 If you want to delete the entire inputted text string, press the button.

 If you want to close the keypad, then press the button at the right top.

Note The Enter key is deactivated and cannot be used if there is no inputted
text string.

Expression keypad
You can enter or edit simple expression.

 Basically, an expression is composed of three input items.

- Green input field: You can enter fixed variables and numbers.
- Orange input field: You can enter an arithmetic operator.

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 Add an expression: Select a green input field and press the Add button. The selected green
input items will be changed to the three basic input items and added into the parenthesis.

 Delete an expression: After selecting any item in the parenthesis, press the Delete button.
The basic input item added into the parenthesis will be deleted.

 If you want to delete the selected input item, then press the Clear key.
 If you want to display the inputted expression, press the Enter key.

 If you want to close the keypad, then press the button at the right top.

 Clicking the script mode button allows you to enter a free-form equation, such as a
script. If this mode is selected, a list of functions available in the script is displayed.

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Chapter 6 Registering Robots and Users

After installing the robot, turn on the system for the first time. Only the Management
menu will be seen. If there is no robot registered, other menus will not be seen.

6.1 Managing Robots

You can register a new robot to be linked to the controller or change the robot name.

In the main menu, select Management > Robot.

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Registering robots

1. Press the Add button.

2. Add a robot and press the OK button.

3. Enter the robot name and press the Apply button.

4. When the restart confirmation window appears, press the OK button.

 You must restart the system for normal operation.

Modifying the robot name

1. After pressing the text box having the robot name, modify it as you want.

2. Press the Apply button.

Registering Force Torque Sensor

1. Click the Add button on the registered Robot screen.

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2. Select the Sensor. It only supports ATI Axia80 at the moment.

3. Press the OK button.

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6.2 Managing Users

You can make sure only specific users can use the software by registering them. Also,
you can grant an individual right to each user to limit their access to the menus.

In the main menu, select Management > User.

Adding users and setting authorities

1. Press the Add button.

2. Set the user information and their authorities and press the OK button.

 The length of text that can be inputted is limited as follows.

- Name: 25 letters
- ID/Password: 20 letters

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 You can choose one of the following two authorities.

- Admin: Can use all the functions of the software.
- Operation: Cannot use the safety and the critical setting functions. Settings
can be all inquired about.

Note  If you are an operation user who lost the password, ask the admin user.
The admin user can modify the password for an operation user.
 If the admin user's password is lost, then contact local distributor.

Menu available to each authority

Depending on the authority set in User Management, the following menus become
available. Even if you are not logged in, you can still use some menus.

Main menu Sub menu Admin Operator Log Off

Robot Operation O O O
Programming O O X
Robot Status O O O
Monitoring I/O Status O O O
Utilization O O O
TCP Setup O O X
Mounting O X X
I/O Setup O O X
Robot Setting
Coordinate O O X
Global Variables O O X
I/O Bit Operation O O X
Motion Limit O △ X
Safety I/O O △ X
Safety Setting
Safety Boundary O △ X
Safe Guard O X X
MODBUS TCP O O X
Device Setting
Vision System O O X

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Main menu Sub menu Admin Operator Log Off

User O X X
Robot O O X
Management
Log O O O
Setting Management O O X
General O O X
SW Network O O O
Configuration SW update O O X
Shutdown O O X
Zeroing Robot X X X

Note  The Zeroing Robot menu is only accessible by the Super Admin
user.
 If you need assistance with zeroing, contact the manufacturer or a local
distributor.

6.3 Login/Logout

Logging in

While logged off, the icon is displayed at the right top of the screen. After finishing
registering a user, while logged off, press the icon and enter your ID/password and
press the Login button.

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Logging out

While logged in, the icon is displayed at the right top of the screen. While logged in,
press the icon and press the Logout button.

6.4 Checking Status

Checking Robot Status

You can check the status of the robot through the robot icon next to the robot name
and the status icon in the upper right of the screen.

 Green : Servo On
 Red : Servo Off

Checking errors

You can check errors that occur while the robot is in operation or being programmed
when error status is shown by the status icon on the top right of the screen.

 Red number: Shows the number of errors that occurred

When you click the icon, an error message is displayed, as shown in the figure below.
The error message shows the error title, error details, error target, and error time.

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Checking the software version

You can check the current version of the operating software and control software by
clicking the information display icon at the top of the screen.

 Operating software: Displays the operating software version.

 Control software: Displays the control software version.

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Chapter 7 Setting Robots

7.1 Setting the Robot Installation Angles

After installing a robot, you must set the robot installation angle.

The purpose of this process is to make sure that actual operation of the robot arm looks
same as what we saw in the preview screen and let the controller know the direction of
gravity.

Warning
The system is unable to automatically recognize the tilt of the ground where the
robot arm's base is installed and the working range, so before operating the robot,
you must enter accurate inputs depending on the installation type.

In the main menu, select the Robot Setting > Mounting menu.

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1. Depending on the tilt of the ground where the robot arm's base is installed, set the
angle accordingly.
 If installed on the ground, then press 0°, if installed on the wall, press 90°, or if
installed on the ceiling, press 180° to set the tilt value more quickly.

 You can touch the gauge or press the left/right buttons to fine tune the tilt
for the X/Y axis.

 You can touch the input window to enter the angle value directly.

2. Press the Apply button to apply the settings to the system.

Press the Cancel button to revert to the previous settings.

7.2 Setting TCP

When you mount a tool in the robot arm for the first time, you must also set the TCP
(Tool Center Point). By setting the tip location/direction and the weight of the mounted
tool, you can calculate the robot's motion.

You can set a different TCP for each of multiple robots linked, and if you want to use
multiple tools for a single robot, then you can save different settings and retrieve and
apply them to a newly replaced tool.

To set the TCP, in the main menu, select Robot Setting > TCP Setup.

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Warning
If the TCP profile is incorrectly entered, accidents such as collision and jamming
may occur while operating the robot and the robot may operate incorrectly while
using the direct teaching function. In addition, as the singularity of the robot arm
may vary depending on the TCP, the program previously prepared may not work or
the robot arm may not operate as expected. Make sure to enter the correct value
according to the TCP type before operating the robot.

Creating a new TCP profile

1. Press the Add button.

2. Enter the new TCP name and press the OK button.

You may enter up to 25 characters. Special characters other than '-' and '_' are
not allowed.

3. Enter the TCP information.

 Position: Enter the coordinate values (X, Y, Z) with respect to the center of the
cross section of the location where a tool is mounted. The unit is in mm.
 Orientation: Set the tool direction (Rx, Ry, Rz).
 Center of Gravity: Set the center of weight for a tool.
- Check the checkbox to enable the option.
- If you do not use the option, all the values are set to zero.
- Min:-700, max: 700, The unit is in mm.

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 Tool Length: Indicates the tool length.

- The tool length is automatically calculated but users cannot enter it on their
own.

 Payload: Set the tool weight.

- If not specified, it will not be saved and an error message will appear.

4. Press the Save button.

 If successfully saved, then the Set Active TCP button is activated.

5. If you want to apply the newly set TCP profile to the robot, press the Set Active
TCP button.
 The robot will receive the currently selected TCP profile setting values.

Note  If no TCP is set in the robot, then the “Empty” TCP is set by default.
 Default settings for Empty TCP: Position (0,0,0); Orientation
(0,0,0); Center of Gravity (0,0,0) with the Use check box cleared.

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Calculating the TCP position

By using the direct teaching function, you can calculate the position of TCP.

To calculate the position of TCP accurately, receive the position data from various
angles with respect to one point and analyze them.

After moving a tool to face a certain point at P1, enter the position data. After that,
move to an arbitrary point, P2 and let it face the same point and enter the position data.
Proceed this way until you have at least three points. The angle between each point (A,
B) should be at least 10°.

Note  A tool is not included in the product package.

 The TCP location may not be calculated correctly depending on the tool
shape or the TCP movement.
 Since only the TCP location is calculated, you should enter the weight
and the center of gravity of the tool before direct teaching.

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To calculate the position of TCP, proceed as follows.

1. After pressing the Edit button, press the Position button.

2. Press the Teaching button.

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3. Press the P1 button when it is activated.

 If you press the P1 button, the Manual Move screen will appear.

4. While pressing down the Direct Teaching button in the Manual Move screen,
move the robot arm to place the tip of the tool right at the reference point.
 For more descriptions on the Manual Move screen, refer to 5.3 Manual Move
Screen.

5. In the Manual Move screen, press the OK button.

6. When the P2 button is activated, repeat steps 3 through 5.

 An error will occur if the previously inputted coordinate and the currently
inputted coordinate do no differ by more than 10°. The point button with errors
will be marked in red. If an error occurs, then you need to change and reset the
angle for that point.

 The more the point data is, the more accurate the calculation result becomes.
You can set the maximum 10 points.

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7. Press the Calculate button.

 The Calculate button will be activated only if the minimum three points are set
properly.

8. Check the calculated position result and press the Apply button.
 Press the Cancel button to cancel the task.

Setting the TCP orientation

You can calculate the orientation of the tool in the tool coordinate system
automatically.

1. Press the Edit button and press the Orientation button.

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2. Press the Set Orientation button.

 If you press the Set Orientation button, the Manual Move screen will
appear.

3. In the Manual Move screen, use jog control and Direct Teaching button to
adjust the tool orientation as follows.
 For more details on the Manual Move screen, refer to 5.3 Manual Move
Screen.
 As shown in the figure below, let the Z, -X, and Y axes for the tool face the same
direction as the X, Z, and Y axes for the robot base respectively.

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4. In the Manual Move screen, press the OK button.

5. Press the Apply button to apply the settings to the system.

 Press the Cancel button to cancel the task.

Changing the TCP profile name

1. Select the TCP setting profile to modify.

2. Press the Edit button.

3. Press the Rename button.

4. Enter the desired name and press the OK button.

 You can enter the max 25 letters but cannot use special characters.

5. Press the Save button.

Editing the TCP profile

After checking the name of TCP profile currently used by the selected robot, and
proceed as follows.

1. Select the TCP profile to edit.

2. Press the Edit button.

 You cannot edit the TCP profile currently being used by another robot.
 You cannot edit an empty profile.
 While you are editing it, the Set Active TCP button is deactivated.

3. When you are finished with modifications, press the Save button.
 When you are finished with saving, the Set Active TCP button is activated.
 If you want to revert the modified settings to the previous setting, then press the
Cancel button.

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Deleting the TCP profile

After checking the name of TCP profile currently used by the selected robot, and
proceed as follows.

1. Select the TCP profile to modify.

2. Press the Delete button.

 You cannot delete the TCP profile currently being used by another robot.
 You cannot delete an empty profile.

3. Press the OK button.

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7.3 Setting Inputs/Outputs

By changing the name of I/O used by the controller, you can make sure they are easily
detected and also assign a function to be executed depending on the input/output
signals.

In the main menu, select Robot Setting > I/O Setup.

Types of digital I/O

There are three types of digital I/O as follows.

 Redundant I/O: Input and output with duplexed connections for the safety purposes.
 General I/O: Input and output for general purposes.
 Tool I/O: Input and output related to tools.
 SafeGuard I/O: Input Of Safeguard Stop.

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Editing the digital inputs settings

Press the Edit icon for the digital I/O item to modify. The following edit window
will appear.

 Name: Use a name easy for a user to identify or the existing name.
- You cannot use the same name already in use by another I/O.
- Max 15 letters (30 bytes) are allowed. Special characters cannot be used.

 Command: Set the command to be executed when the preset value (Low/High) is
inputted or outputted to the I/O terminal.
- Unassigned: The I/O is not used.
- Program Play: Start the program.
- Program Stop: Stop the program.
- Program Pause: Pause the program.
- Reduced Mode: Reduce Robot Speed.
- DirectTeaching Mode: Switch Robot to Direct Teaching Mode.

Note You can only change the name, if it is a redundant I/O.

Editing the digital outputs settings

Press the Edit icon for the digital I/O item to modify. The following edit window
will appear.

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 Name: Use a name easy for a user to identify or the existing name.
- You cannot use the same name already in use by another I/O.
- Max 15 letters (30 bytes) are allowed. Special characters cannot be used.

 Command: When the robot is in the state of the set command, the value set(Low/High)
to the output terminal is output.
- Unassigned: The I/O is not used.
- Program Running: Outputs the set value when the program is executed.
- Program Stopped: Outputs the set value when the program stops.
- Program Runtime Error: Outputs the set value when error occurs.

Note You can only change the name, if it is a redundant I/O.

Types of analog I/O

There are three types of analog I/O as follows.

 General I/O: Input and output for general purposes.

 Tool I/O: Input and output related to tools.

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Editing the analog I/O setting

Press the Edit icon of the analog input or output item to modify and the editing
window will appear as follows:

 Name: Use a name easy for a user to identify or change the existing name.
- You cannot use the same name already in use by another I/O.
- Max 15 letters (30 bytes) are allowed. Special characters cannot be used.

Note For analog I/O, you can only change its name.

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7.4 Coordinates

You can set the location information that is available in the program and other setup
menus.

From the main menu, select Robot Settings > coordinates.

 Point: Add a point.

 Line: Add a line consisting of two points.
 Plane: Add a plane consisting of 3 points.
 Coordinates generated by a point, a line, and a plane are available when you a
variable is selected.
Points consisting of each of them are available when Enable is selected.
When you select the name of a point, the input tool that allows you to edit is displayed.
(Up to 25 characters)

Registering points
You can add and set point coordinates.

 The position where the point coordinates are set becomes the reference position, and
the coordinate system is set to the same coordinate system in which TCP was set.

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Registering line coordinates

You can add and set line coordinates.

 Click point 1 and point 2 to set two points to define a line.

 Coordinate system information
- Reference point: The first point becomes the reference point.
- Y axis: The direction of the first point to the second point is the Y axis.
- Z axis: This becomes the robot's Z axis.
- X axis: This is set to the other axis.

Registering plane coordinates

You can add and set plane coordinates.

 To define a plane, set point 1, point 2, and point 3 in sequence.

 Coordinate system information
- Reference point: The first point becomes the reference point.
- Y axis: The direction of the first point to the second point is the Y axis.
- Z axis: Select the Z axis using the right-hand rule in three rotation directions
together with the third point.
- X axis: This is set to the other axis.

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7.5 Setting Global Variables

You can set the global variables that are available and shared by many programs by
restarting the system.

 Variable name: Specifies a variable name.

- Up to 10 characters (20 bytes) can be entered.

 Variable value: Specifies a variable value.

- Range : -2147483647 - 2147483647

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7.6 I/O Bit Operation

You can combine the values of multiple digital I/O inputs, and assign them to variables
or assign them to actions.

Add/Delete
Add or delete bit operation settings.

 Clicking the Add button adds one setting, and the initial value of each IO is displayed as
Low.
 The Delete button is enabled when any check box in a row is selected. If it is clicked, the
selected row will be deleted.
 Settings cannot be added while the program is running or started.

I/O bit operation settings

Set I/O bit operation value and assign a function.

 Each time you click the I/O bit icon, it changes, through a sequence of
Low/High/Disable.
 High is assigned to 1, Low is assigned to 0, and the bit operated value is displayed in the
value field.
 The IO of the bit set to Disable is treated as '0' regardless of the actual value received.

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Chapter 8 Safety Settings

After configuring the installation settings, you must configure the safety settings to
protect users against the dangerous situation that can arise during robot operation.

Warning
Make sure to check safety settings immediately after the robot is installed. In
addition, all of the functions for safety settings must be regularly checked.

8.1 Limiting Robot Movement

To guarantee the user's safety while interacting with the robot, you can make sure that
the angle and speed of robot joint does not exceed a certain limit.

Press Safety Setting > Motion Limit in the main menu.

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Default settings
Depending on the limitation on each item, four sets of default settings are provided.

If you want to use the default setting, check Preset and select one out of the four
choices.

Manual setting method

If you want to set each item on your own, you can use the adjustment bar to change the
value while Preset is not checked. Or, after pressing the input box, you can enter your
own inputs.

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There are several ways to limit the robot's movement.

 Torque: You can limit the max force that the robot(TCP) is exerting to the outside.
 Force: TBD
 Speed: You can limit the max speed for the TCP's linear movement.
 Collision mitigation: This can be set to mitigate the impact of a target object in the
event of a collision.
 Deceleration mode speed (%): Sets the speed in deceleration mode. When
deceleration mode is applied, a red alarm occurs at the top of the screen. Clicking the alarm
moves you to the initial screen.
 Joint Rotation: You can limit the angle of each joint.
 Joint Speed: You can limit the speed of each joint.

Press the Cancel button to revert the settings newly changed by a user in the current
tab (general mode or deceleration mode) to the previous value.

When the settings are complete, press the Apply button to apply it to the robot.

Caution
 The joint speed cannot be limited with the Speed option. You can limit the joint
speed only with the options in the Joint Speed tab.
 If the temperature of the operating environment for the robot arm is not greater
than 10 ℃ during the initial start, collision detection may occur due to the limited
force. If such problem occurs, increase the limit value of Force sufficiently,
operate it at a low speed for about 30 to 60 minutes for preheating, and lower the
Force value to use it.

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8.2 Setting Safety Boundaries

To improve user safety, you can build virtual fences around the robot to prevent the
TCP from moving beyond the boundary of these virtual fences.

Press Safety Setting > Safety Boundary in the main menu.

Adding safety boundary planes

After adding multiple safety boundary planes, if necessary, you can select one of them
and use it.

1. To add a boundary plane, press the Add button.

 If you press the Add button, the Manual Move screen will appear.

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2. In the Manual Move screen, use jog control and Direct Teaching button to set
the boundary position.

 For more details on the Manual Move screen, refer to 5.3 Manual Move
Screen.
 Your safety boundary will be created in a location that is separated from the
center axis of the flange as much as the TCP length set in the TCP.

3. To save the settings, press the OK button.

Viewing safety boundary planes

Press the icon in the View column to hide or unhide the safety boundary plane in the
preview screen.

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 : To display in the preview screen.

 : Not to display in the preview screen.

Press the Info icon to check the coordinates for the safety boundary.

 Point: Indicates the center of the 3-D where the center of the safety boundary is located.
 Direction: Indicates the direction(vector) for the border plane that can indicate a
collision with the safety border in the controller. (Blue Z-axis on the screen)

Applying safety boundaries

1. Activate the boundary for use.

 : To use

 : Not to use

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2. Press the Apply button.

 Press the Cancel button to cancel the modifications and revert to the previous
settings.

Note If there are eight or more safety boundary planes in the list, press the up/
down button to scroll.

Changing the name of safety boundaries

If you add a safety boundary, it will save as "Boundary" and a number by default.

1. Press the name of boundary to modify.

2. Enter the desired name and press the OK button.

Deleting safety boundary settings

1. Select the safety boundary to delete.

2. Press the Delete button.

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3. Press the OK button.

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8.3 Setting Tool Boundaries

The user sets the safety boundary of the set tool, so that the tool does not go beyond the
safety boundary of the set working area.

Adding Tool Safety Boundary Surfaces

The safety boundary of the tool can be set only for TCP settings that have already been
set.

1. Select the Tool Boundary tab and select an item with the name of the TCP you want
to set from the list.

2. When you set the selected TCP to Use, a box-shaped tool safety boundary is
created on the screen by default.

3. The tool boundary surfaces can be set in the following 4 types:

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 Box: Box-shaped boundary surface with TCP as the center having the Z axis of
the TCP as the height and the X axis as the width
 Sphere: Spherical boundary surface with constant radius and with TCP as the
center
 Cylinder: Cylindrical boundary surface with TCP as the center, having a height
in the Z-axis of TCP
 Cone: Cone-shaped boundary surface with TCP as the center, having a height
and direction in the Z-axis of TCP

For
The TCP currently applied to the robot is marked with the .
reference
Each boundary surface of the tool has the same coordinate axes as TCP's
coordinate axes.

Setting Tool Safety Boundary Surfaces

1. The boundary surfaces of the tool set to Use are set to a box by default. The user
selects one of the four boundaries for the shape of the tool or the desired shape.

2. The selected boundaries are displayed on the screen, and the radius, height, width,
etc. are set according to the selected form. In addition, you can move and set them
based on the TCP coordinates, and enter the rotation angle along the coordinate
axis.

Applying Tool Safety Boundary Surfaces

1. Switch the boundary surface you want to set to the TCP to Use or Not Use.

2. Press the Apply button.

Press the Cancel button to cancel the current settings and return to the previous
setting.

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For Pressing the Apply/Cancel buttons simultaneously applies the safety

reference
boundary of the working area to the safety boundary of the
tool.

8.4 Setting Redundant I/O

To guarantee the safety of the I/O terminal or input/output the important data, you can
opt for using a redundant I/O, not a single I/O. If you set the redundant I/O, you are
no longer checking a single I/O value. Instead, the two designated inputs or outputs
check the High or Low signals to determine validity of values.

In the main menu, press Safety Setting > Redundant I/O.

There are two tabs - digital input and digital output. Select the tab to set and proceed as
follows.

 In case of digital inputs, the function will operate if the input is high or low.
 In case of digital outputs, the high or low signal is sent for the assigned function.

1. Press the Add button.

2. Select an I/O terminal to be used as redundant I/O.

3. Set the function to be assigned.

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 You can assign the following functions to digital inputs.

- Unassigned: The function is not assigned.
- Emergency Stop: If the two designated inputs are all Low (0) and the
actual emergency stop button is released, it operates as if the emergency stop
button is released; and if any of the inputs is High (1), it operates as if the
emergency button is pressed.

 You can assign the following functions to digital outputs.

- Unassigned: The function is not assigned.
- Emergency Stop: If the two designated IOs are in the emergency stop state,
Low (0) is output. Otherwise, High (1) is output. When a physical emergency
stop button is pressed, it operates even when the designated IO is in the
emergency stop state.
- Robot Moving: If the robot moves, the designated output terminal outputs
Low (0). Otherwise, it outputs High (1).
- Robot Not Stopping: The designated output terminal outputs High (1) till
the time point when the stop command is performed after the stop command is
ordered to the robot. Otherwise it outputs Low (0).

4. Press the Apply button.

 Press the Cancel button to revert to the previous settings.

Note User can name each I/O on their own. For more details, refer to 7.3 Setting
Inputs/Outputs.

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8.5 Setting Safeguard I/O

The user sets the safeguard stop.

In the main menu, press Safety Setting > Safe Guard.

 Assign a Safeguard Stop function with the IO.

 Click Apply button to apply to the system.

Note Only one Safeguard Stop can be set at a time. Assigning a function to
another input will release the function that was previously assigned to the
input.

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8.6 Exceeding Safety Limit of Joints

If the safety limit of any joint is exceeded, information on the joint exceeding the safety
limit is displayed at the top of the screen, as shown in the figure below.

If the safety limit of a joint is exceeded, the system will not operate normally. Therefore,
the operating range must be safely set to the normal range, through the following
procedure.

1. Go to the administration screen by selecting the administration

menu or clicking the top guidance message.

2. Uncheck 'Use Safe Settings.'

3. Click the 'Reset' button to perform a reset, then click the 'Start'
button.

4. Click Manual Manipulation at the bottom left to go to the manual

control screen.

5. Joints that exceed the safety limit are controlled to be within the
normal range by using the jog button.

6. If they are within the normal range, return to the operating

screen.

7. Check 'Use Safe Settings'.

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Chapter 9 Programming

You need to program the movement ahead of time if you want your robot to perform a
certain task.

To program your robot, select Programming in the main menu.

9.1 How to Use Commands

Selecting a flowchart
There are two types of flow charts - main and sub.

 Main Program: In this screen, you can input or modify the main program.
 Sub Program: In the main program, you can call multiple sub programs for use. Press
the Sub tab to move to the screen where you can create or edit a sub program. For more
details about the sub program, refer to 9.16 Using a Sub Program.
 Thread Program: This is a program creation screen that is executed in parallel with the
main program.

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Type of commands
You can use the following commands in your programming - Move, If, Loop, Switch,
Halt, Wait, Set, Loop, Pattern, Sub Program, and Vision.

Set the point that the TCP will move to.

Move
For more details, refer to 9.7 Move command .

Branch the commands based on the conditions.

If
For more details, refer to 9.8 IF Command .

Repeat a specific command.

Loop
For more details, refer to 9.9 LOOP Command .

Branch the command for each case of the designated variable.

Switch
For more details, refer to 9.10 SWITCH Command.

Tell the robot to wait until the condition entered by the user is
Wait
met. For more details, refer to 9.11 Wait Command .

Create output signals, variables and TCP profile.

Set
For more details, refer to 9.12 Set Command .

Sub Call a sub program.

Program For more details, refer to 9.15 Using a Sub Program .

Variables You can manage the variables required for program creation.

Indicates that additional commands can be used in addition to

Commands
the basic commands.

Provides editing functions such as copy, cut, paste, delete, and

Edit
move to the icons of the currently created program.

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Additional Commands
In addition to the basic commands, the additional commands that appear when the

View Command button is clicked are Folder, Message, Halt, Conveyor, Vision,
Pattern, Script, and Path.

Groups the created program command icons and bundles the

Folder
programs into a sub-folder.

Message Define Message Type.

Halt Terminate the program.

Conveyor Set the operation to be linked with conveyor’s movement..

Use a vision equipment to scan an object.

Vision
For more details, refer to 9.18 Vision Command.

Tell the robot to move according to the predefined pattern.

Pattern
For more details, refer to 9.15 PATTERN Command.

Script Provides Editor to edit scripts.

Enables the user to directly grasp the robot arm and create
Path
motion in order to generate the motion of the robot.

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Entering commands
Each time you press a command, it is inputted in the timeline one by one.

 After programming is complete, select the icon to repeat the entire program
continuously.
 If it overflows to the next screen due to too many commands in the flow line, you can press
the up/down or left/right buttons to scroll.
 At the start of the program, you can initialize variables, IO, robot posture, etc. using the

initialization icon . This initialization icon cannot be deleted.

Check Icon Status

The status of the icon indicates the status of the newly added command and the
modified command.

 Command that do not change any parameter after adding new.

 Command which value has been modified.

 When the program is saved, the current icon state is maintained.
 When clicking the Apply button, all icons are changed to normal state.

Changing command names

Each command offers an option necessary for execution. The same command yields a
different result depending on the option setting, so you can designate a different name
for each command.

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After entering a command in the timeline, press the command name to modify the
name.

Deleting commands

1. Select a command to delete in the timeline.

2. Press the Delete button.

Searching Commands

1. Click the Search button to display the search function on the screen.

2. Enter the name of a command to be searched, and perform a search.

3. If there is a searched command, the number of searched commands is displayed,

and you can easily find the command by using the left/right navigation button.

Skipping Commands
For each command created in the program, you can skip without executing a specific
command during program execution.

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1. Check the Skip setting.

2. Commands that have been set to Skip are grayed out, and will not be executed
during program execution.

Tree

If you click the , all the commands programed are displayed in Tree structure.
The commands in the Tree and the command icons in the flowchart are displayed in
synchronization with selection or program progress.

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9.2 Setting Variables

You can manage variables such as adding/deleting/modifying variables to be used in the

program. Press the variable management menu button at the end of the command list.

When you press the variable management button, a screen for variable management
and monitoring is displayed at the top, as shown below.

Adding variables
Press the Add button. If you press the Add button, the default name and value (0) will
be automatically entered.

- Number : Variables to store numbers

- String : Variables to store string

- Boolean : Variables of True or False type

- Position : The Position of TCP

- Joint : The Values of Joints

- Array : Array type variables

If you select a variable type, the variable is automatically entered with the default name.

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Modifying variables

1. Press the field if you need to change the variable name or value.

2. Change it to the desired name or value and press the OK button.

 The max length of variable is limited to 10 letters.
 For a variable value, you can only enter a number. The range is from
-2147483647 to 2147483647.
 Character variable’s maximum length: 20 characters

Deleting variables

1. Check the checkbox for the variable to delete.

2. Press the Delete button and press the OK button.

Variable Monitoring
You can check the number of currently registered global variables and the real-time
values of variables registered in the robot. Numeric variables are displayed with up to
four decimal places, rounded to five decimal places.

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9.3 Editing programs

If you want to change the order or structure of commands entered in the timeline, then
press the Edit menu button at the end of the command list.

Note You can also press the command in the timeline for more than three
seconds to open the Edit menu.

Overview of edit menu

Cut the selected command. You can crop a

Cut
command to another location.

Paste the cropped or copied command to the

Paste
selected location.

Copy the selected command. You can copy a

Copy
command to another location.

Delete Delete the selected command from the program.

Left or Move the selected command to the left or right

Right in the timeline.

Applies the values of several selected Move

Batch
commands in batches. It is activated when you
Apply
select the same move command.

Combine Create a folder at the end of the program and

Folder move selected icons below.

Clear
Cancel the selection of the command.
Selection

Close the program editing mode and return to

Close
the program screen.

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Example of program editing

In this example, you can cut a command entered in the timeline and paste it onto
another location.

1. Select a program command to be pasted onto another location.

 The red number marked when a command is selected indicates the order of
pasting.

2. In the edit menu, press the Cut button.

 After pressing the Cut (or Copy) button, the Select Mode button will be
activated, so that you can cancel the edit command and return to the Select
Mode again.

3. Select a location to paste it to.

 Space between commands cannot be selected, so you must select the command
right before the location of pasting.
 Once a location is selected, the Paste button in the Edit menu will be activated.

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4. Press the Paste button.

Undo Function

You can use the edit function to undo edits made

Undo
to items.

Redo You can redo an edit that has been undone.

Note . Up to 50 steps are saved.

. The edit history is initialized when you open a New File, File Open or
Cancel.

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9.4 Managing a Program

At the bottom of the programming window, press the File button to save, load or
delete the program.

Saving a program

1. To save the completed program, select File > Save at the bottom of the screen.

2. Enter the program name and press the OK button.

 Only if the program is newly saved or saved with a new name, the name input
window will appear.

If you want to save the program with a different name, press Save as and enter the
name and then press the Save button.

Making a new program

If you want to make a new program, then select File > New at the bottom of the
screen.

Note Enter the program name when you apply or save a program.

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Loading a program

1. To load the saved program, select File > Load at the bottom of the screen.

2. Select a program to load and press the OK button.

Deleting a program

1. To delete the saved program, select File > Load at the bottom of the screen.

2. Select a program to delete and press the Delete button.

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Export as script

1. To save the program as a script, select File > Export as script at the bottom of
the screen.

2. Enter the file name and press the OK button.

Export Program File

You can save the program and the configuration file of current system

1. To save the program, select File > Export Program File at the bottom of the
screen.

2. Select a folder to save and press the Delete button.

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9.5 Using Templates

You can save the prepared program structure as a template. Only the entire program
structure is saved but the option for each command is not saved.

Saving as a template
To save the completed program as a template, select Template > Save at the bottom
of the screen.

If you want to save the template with a different name, press Save as and enter the
name and then press the Save button.

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Loading a template

1. To load the saved template, select Template > Load at the bottom of the screen.

2. Select a template to load and press the OK button.

Deleting a template

1. To delete the saved template, select Template > Load at the bottom of the screen.

2. Select a template to delete and press the Delete button.

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9.6 Applying programs

Before applying the program results to the robot or actually using it, it is necessary to do
a simulation.

If you want to link the program to an actual robot or check it in previews, press the
Apply button. To revert it to the previous settings before the changes are made, press
the Cancel button.

 To check it in preview, select Simulation.

 To link it to a real robot, select Real Robot.
 The entire program speed can be adjusted by using the Speed slide bar.

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9.7 Move command

The command is used to move the robot arm by designating the destination and the
movement method.

Selecting a movement method

There are three ways to move as follows and you can set the tool speed and acceleration
for each method.
 Linear: A tool moves linearly between the starting point and the end point. To make the
tool movement path a straight line, each joint tends to move in a more complex way.
- Frame: Select whether to move by TCP or Flange.
- Reference coordinate system: Select the reference coordinate system on which
the robot moves when executing the move command.
- Speed: 0.1 mm/s ~ 1000 mm/s
- Accel. (Acceleration): 0.1 mm/s2 ~ 2500 mm/s2
- Don’t stop at this point: This is a setting that allows you to move at a constant
speed without stopping operation between move commands. For details, refer to Move
without stopping.

 Joint: The tool movement path between the starting point and the end point is ignored
but the movement of joint is minimized, instead.
- Speed: 0.1 deg/s ~ 180 deg/s
- Accel. (Acceleration): 0.1 deg/s2 ~ 360 deg/s2

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 Arc: A tool moves along the circumscribed circle whose center is the circumcenter of a
triangle formed by the starting point(S) and the two points (W1, W2).
- Speed: 0.1 mm/s ~ 1000 mm/s
- Accel. (Acceleration): 0.1 mm/s2 ~ 2500 mm/s2

Note The TCP coordinates of the last position held by the robot are the
coordinates of the starting point.

 Circle: The tool moves along the circle formed by the start point (S) and the two
waypoints (W1, W2).
- Speed: 0.1 mm/s ~ 1000 mm/s
- Accel. (Acceleration): 0.1 mm/s2 ~ 2500 mm/s2
- Rotation Count: 1 ~ 50 (Default 1)

Note The starting point is the TCP coordinates of the robot’s last posture.

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Radius of Linear
If you use the radius in Linear movement and the next command is Linear movement, it
moves the curve without stopping when moving between commands.

 The minimum radius is zero. If you set the radius to zero, then its path is not a curve.

Don’t stop at this point

This is a setting that allows the robot to move at a given speed without stopping
operation between motions. If the currently set move command is Move Linear and the
next move command is the same straight line motion, the robot will move without
stopping.

 If P1 and P2 are linear motion and the radius is 0, the move commands of P1 and P2 should
be on the same straight line with respect to the start position (S), as above.

However, if the set travel command does not reach the set speed or if the next move
command is not on the straight line, an error may occur and the robot program may
malfunction or not perform.

Blending
Combines with all Move commands to move in series without interruption.

(It doesn’t support Move C)

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 Select Blending (You can’t use it at the same time with Don’t stop at this point function)
 Enter the radius. The maximum radius is calculated based on the coordinates of the next
move command as below.

- Moving path when radius within driving range

Mp : Start point of blending

Mc : Waypoint of blending and
the center of radius
Mn : End point of blending

- Limitation of Radius length

The maximum length of the radius that can be set is limited to 50% of the shorter
distance between D1 and D2 that is greater than zero.

D1: (distance Mp & Mc) / 2

D2: (distance Mc& Mn) / 2

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Advanced
The command is used to control digital output while moving.
 Select Advanced

 Add the digital outputs to control and set the values of them.

Setting the coordinates for movement

To set the movement coordinates, you can either use an absolute value that is fixed in
the space or a relative value that is relative to the previous location.

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 Fixed Point: The 3D coordinate is received from the robot's coordinate system and used
as the movement coordinate.
- Press the Set button to launch the Manual Move screen. For more details about the
Manual Move screen, refer to 5.3 Manual Move Screen.

 Relative: You can set the movement coordinate with respect to the previous location.
 Variables: You can set the position variable specified as a local variable.

Note The inputted coordinate is examined in the control software whether it

indicates an area where the robot can move to. Even if you entered an input
within the range, an error can occur when the area is prohibited by the
safety setting or physical restrictions.

After setting the coordinates, press the Move button to move the robot arm to the
coordinate where a tool is set.

Displaying as groups
If the move commands are repeated two or more times, then you can use one icon to
indicate them all.

In the flow chart, press the group button, then they will be grouped as one. The
number of commands in a group will be indicated by a number at the right top of the
group icon.

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9.8 IF Command

Use the command to initiate different commands depending on the condition.

Enter the condition in an IF statement.

 Press the text box to launch the formula keypad. For more details about the formula
keypad, refer to 5.4 Virtual Keypad .
 If you use an IF command, an if statement will be created below the main flow.
 Select the Use Else checkbox to create an else statement below the if statement.

 Add Else IF to add another condition under the if statement.

- To add Else IF under IF, then press the + Else IF button.
- To delete the Else IF statement you added, select the checkbox for the Else IF statement,
and press the Delete button.

 If you select the icon on the right side of the conditional statement as shown below, you can
program to check the conditions of the conditional statement in real time.
- Even if the IF condition is judged to be true, the condition is checked in real time while
executing the program. If the condition is False, the execution of the program command
is stopped and the upper or lower conditional statement is executed.
- When If is executed
: If Else is present, execute the program command with the Else condition.
If Else is not present, execute the next program command of If.

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- When ElseIf is executed

: If ElseIf is present in the child, execute the ElseIf program command that meets the
current condition.
If Else is present in the child, execute the Else program command.

9.9 LOOP Command

Use the command to repeatedly execute a series of commands.

 Disabled: Do not use a LOOP command.

 Always: Repeat execution.
 Loop input times: Repeat as many times as the entered number.
- By default, it is set to one.
- Max: 1,000,000

 Execute loop based on input: Repeat execution until the condition entered by the
user is met.
 Real-time condition check
Loop condition is judged to be true, and the program corresponding to the condition is
executed. When the condition is checked in real time and it becomes False, the executing

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command is stopped, the Loop command is stopped, and the next program command is
executed.

9.10 SWITCH Command

Use the command to execute a different command depending on each specific case. An
IF command is executed after assessing all the conditions branching to Else IF, but a
SWITCH command is executed immediately by finding the corresponding case, thus it
is much faster than execution of an IF command.

1. Using the drop-down menu next to Switch, select a variable.

For more details about the variable setting, refer to 9.2 Setting Variables.

2. Enter a value corresponding to each case.

 To add a Case, press the + Case button.

 To delete the Case you added, select the checkbox for the Case and then press the
Delete button.
 Click the Break button to select whether use the Break property for each Case
statement. (Default: Use Break)

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9.11 WAIT Command

Instruct the robot to wait for a certain period.

 Disabled: Do not use a Wait command.

 Waiting time: Enter the duration of waiting time.
 Digital: Wait until a digital signal is inputted to a specific digital input terminal.
- For a digital signal, you can choose either of low or high.

 Analog: Waits until the condition of the value set to a specific analog input terminal is
met. On analog setting, whether to use the current (A) or the voltage (V) is determined by
the unit set under the Monitoring menu.
 Input expression: Wait until the conditional expression set by the user is met. You can
enter the conditional expression indicating the waiting condition on your own.

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9.12 SET Command

You can set a digital or analog output value or assign a specific value to a variable or
even change the TCP profile currently in use.

 Disabled: Do not use a SET command.

 Digital: Set a specific digital output value.
 Analog: Set a specific analog output value. The output unit is based on the analog unit
that you set in the Monitoring menu.
 Tool Power : Set the voltage of Tool IO Power.
 Test : Test defined output before running program.

 Variable: Assigns a specific value to a variable added to the variable list and to a register
item set in the MODBUS TCP menu. Press the text box next to the variable selection menu
to launch the expression keypad. For more details about the expression keypad, refer to
5.4 Virtual Keypad .

 TCP: Switch to another TCP profile.

 Payload: Change the payload of current TCP.

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9.13 Folder

Program command icons can be grouped into folders.

Change Programed Icons into Folder

1. Click the Edit icon.

2. Select icons that you want to group into folder.
3. Click the Combine Folder icon.
 When converting a folder, the folder is created at the last location of the program.

Create New Folder

1. In the Commands view, click the Folder icon to create a folder.

2. Add icons to be programmed under the created folder.

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9.14 Message

Displays a user-defined statement or variable in a pop-up or console window.

The command can be added from the Command Extension tab.

Output format
 Pop-up: Displays a pop-up window with messages.
 List: Displays messages in the lower left console window.

Message operation
If you set the message format as pop-up, you can specify the operation accordingly.
None / Suspend / Stop
 If pause is set, you can select whether to continue the program from the popup message.

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Message format
 User message: Outputs the message the user has entered.
 Variable output: Selects the variable to which to output the value.

Select message
 Write a message in advance and save the text file to the USB in UTF-8 format.
 Click Select message.
 Select the created message file and click OK.

 Select the message to use and click Apply.

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9.15 PATTERN Command

If the robot repeatedly executes the same task along the same path, you can define it as
a pattern by using this command.

Pattern types
There exist the following five types of patterns.

 Stack pattern: In this pattern, the robot stacks objects while vertically moving with certain
intervals.
 Unstack pattern: In this pattern, the robot unstacks objects while vertically moving with
certain intervals.
 Line pattern: In this pattern, the robot repeats the same task while moving along the
straight line with certain intervals.
 Square pattern: In this pattern, the robot repeats the same task while moving along the
straight line and in the direction perpendicular to it.

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 Box pattern: In this pattern, the robot also repeats the same task vertically which it
performs in a square pattern.

Setting the pattern coordinates

After selecting a pattern to use, set the coordinates that determine the type of pattern.
The following image illustrates a box pattern.

1. Select the coordinates to set by starting with number 1.

 Select the number for the sample image or press the list of the pattern location
coordinates.

2. Press the Set Point button.

 Press the Set Point button to launch the Manual Move screen. For more
details about the Manual Move screen, refer to Manual Move Screen
 On the Manual Move screen, enter the final coordinate values.

3. Proceed with point setting until you reach the last number.

Setting repeat counts

For every pattern, you need to set repeat counts between the starting point and the end
point on each side.

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 Count (n): the number of repeated movements on a side

 Interval (d): the distance that the robot moved each time

Note  If you do not enter the coordinates, the repeat count or the interval will
not be displayed.
 When the repeat counts are set, the intervals are automatically
calculated and displayed. The intervals are not editable.

Advanced commands for patterns

Sets the display of the currently executing index of the pattern, the moving index using
the variable, and the starting position.

 Start at this position: If 'Start at this position' is checked, the start position is set at the
initial position of the pattern.
 Check Location: While pressing this button, move to the position you entered.
 Select a variable for monitoring: If you want to know the current running index of the
pattern, you can use a numeric variable to monitor for the current moving index.
- Starting index: 0 Base
- After executing the pattern, the monitoring variable is automatically increased by 1.
 Use the position to move as the setting for the variable
: Used to move to a specific position using a variable.
Variables are used together with monitoring variables.

If starting position and variable movement are used together, starting position is given
priority.

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Setting pattern points

If you enter a pattern command in the timeline, then the line to set the pattern point and
the icon will be added. When each pattern repeats, if you immediately move to the
next destination, then you can get interfered by an obstacle. So, by using the pattern
point setting, you can avoid collisions with them and smoothly continue with the next
pattern task by selecting a desirable tool path.

Press the pattern point icon to launch the following setting screen.

The options for the pattern point settings are the same as the linear movement options
in the move command section, and additionally you can insert move commands before
and after the pattern point to adjust the tool path.

Note Only a linear type of move command can be used before and after a pattern
point.

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9.16 Using a Sub Program

In the main program, you can call multiple sub programs for use.

Making a sub program

1. In the flow chart, press the Sub tab.

2. Press the subprogram button in the command menu of the Sub tab.
 Once the subprogram button is pressed, a new sub program will be created.
 The name of the sub program is automatically generated.
 To delete the sub program, press the Delete button at the top or press the Edit
> Delete button.

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3. After pressing the sub program, create a program that will be used as a sub
program.
 Once the sub program is pressed, available commands will appear in the
command menu and a time line will be created, so that you can prepare a
program.

Saving and loading a sub program

After creating a sub program in the Sub tab, you can save it as a file or load the sub
program or template.

 Keep Sub Program : Even if the original subprogram is changed, the contents of the
program at the time of loading can be preserved, and even if modified by another
program that shares the subprogram, the operation at the time of loading the
subprogram can be preserved without being affected.

Entering a sub program

After creating and saving a sub program in the Sub tab, proceed as follows to use it in
the main program.

1. Enter the subprogram command in the main program.

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2. Press the Sub-program button.

 After selecting a sub program, the sub program name will be displayed on the
button.

3. Select a sub program for use and press the Select button.

Once a sub program is selected, the subprogram command will be added to the
timeline as shown below, and a sub program line will be added at the bottom to indicate
the content of the sub program.

In the main program, you can also modify the content of the sub program. Since the sub
programs in the main and sub tabs are linked to each other, modification made in one
of them will be also reflected in the other.

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Note In the main program, you can modify the content of sub program but you
cannot save it. If you want to save modifications made for the sub program
in the main program, you must save it in the Sub tab.

9.17 Conveyor

Executes operations linked with conveyor movement.

Conveyor Setting

 Direction : Set the conveying direction information of the conveyor. Select the line
coordinates created from the coordinate settings.

 Position offset: Set the distance to delay tracking start.

 Conveyor Speed: Set the conveying speed of the conveyor. Select the Number variable or
type the value directly.

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Conveyor Start Options

If the I/O set in the trigger satisfies the condition, it starts tracking the conveyor.

 Trigger : Set the I/O and condition that trigger the start of conveyor tracking. Only Digital
Input is available.

Setting Conveyor Command

Set the actions to be executed during conveyor tracking.

 During conveyor tracking, the robot moves to the Move position specified by the conveyor
moving direction. Only Linear Move can be set in the conveyor.
 The real-time monitoring function of If and Loop can not be set for operation during
conveyor tracking.
 Conveyor tracking is finished when all work in the conveyor tracking is complete.

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9.18 VISION Command

You can communicate with a vision equipment by using the vision data configured in
the Device Setting menu.

Setting basic options

Press the drop-down menu to select a desired vision equipment and set the waiting time
and the data receiving option.

Setting the movement speed

Once you have entered the vision command, a vision capture point and a moving
point will be created below the vision command.

You can set the vision capture point on the following screen.

You can set the movement speed/acceleration for a vision camera attached in the robot
to move to the recording location.

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 The same input range of speed/acceleration is used as in linear movement.

 Variable setting: If there is a variable registered by the user, it can be used to store whether
to recognize the vision. If you select a variable, it stores the success or failure during
program execution, and you can program it using the corresponding variable in the next
program. Conversely, if you do not select a variable, when the vision fails, the program will
not proceed any further.
 Since the scan position is configured in the Device Setting menu, you do not need to set
it in the vision command again.
 Wait time(s): After a vision equipment moves to the recording location, it may require
some waiting time until the robot arm's position is stabilized. (No waiting time is required
depending on the robot speed.) Set the waiting time for responses after requesting data
from a vision equipment.
- Default: 3 sec
- Input range: 1 ~ 10

 Read and Fail Options: You can set the number of data requests in case data receiving
is unstable.
- Request count: The input range is 2 ~ 10.

Setting the movement location

After a vision equipment arrives at the location, you can use an additional Move
command to adjust the Z-axis for the TCP. You can use a Move command under a
Vision command as follows.

 The same input range of speed/acceleration is used as in linear movement.

 The X, Y coordinates and the RX, RY, RZ coordinates used are received from a vision
equipment and only the Z coordinate can be set to user's preference.

Note If you want to use a tool such as a griper, you will need to input the set
command additionally.

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9.19 Thread

When a robot program is executed, it is possible to execute parallel programs that

require IO and other controls in parallel with the Main program. However,
Move-related commands cannot be used.

Thread Tab
Select the Thread tab to create a thread. Click the drop-down menu to select the vision
device you want to use, and set the wait time and data reception options.

 Repeat: Selects whether to repeat the program.

If it is not checked, thread will be executed just once.
 Interval: Set the execution interval.

Thread Creation
Multiple threads can be created. Like a sub-program, each Thread is clicked on as an
icon and added to the timeline in the lower layer.

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Note Commands to control the motion of the robot cannot be used.

Event Tab
Create Thread which has condition. Select the Event tab to create a Event.

It’s same with Thread except using condition.

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9.20 Script

Provides the function to edit the robot script and set it as a robot command.

Script Viewer
Displays a created script. While the program is running, a line currently proceeding in
real time is displayed on the screen.

 EDIT: You can edit the edit window by opening it.

- Click the Validation Check button to check the integrity of the created script.
- Manual Control: Operate the robot manually and get the coordinates of TCP, Flange,
and Joints.
- Functions : Available functions can be added to Script by clicking on them.
- Variables: Available variables can be viewed and used.

Note For script commands, refer to the separate manual.

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9.21 Path Command

You can create a motion by holding the robot arm directly.

Recording Paths

1. Starting to record

Click the button and move the robot arm along the path you want to record.
During recording, the recording status is displayed in a pop-up window, and can
be canceled or stopped.

During recording, you cannot move to another screen or perform other operations.

If an already created path is found, it will be deleted and a new one created.

2. Path Playback

If there is a recorded path, it will perform its motion.

 S: Move to the beginning of the path.
 E: Move to the end of the path.

3. Apply

Once you have confirmed the motion, click the Apply button to save it as a file.
 Speed: Sets the execution speed of the recorded motion.

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 Import: Imports an already recorded motion.

 Export: Saves the recorded motion separately.
 Deduplicate path at the ends: If there are the same postures at the start and end
points in the motion recording process, they are deleted.

Note To execute the recorded motion, the Move coordinates immediately before
the Path command and the start coordinates of the Path must match. Press
the S button to move to the start position, and match it with the
coordinates of the previous Move command.

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Chapter 10 Starting the Robot

Starting the robot means that you are powering up the servo motor and get ready for its
operation.

Select Robot Operation in the main menu.

Note If your robot is already registered, then it will appear in the initial screen
after booting up the system.

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Turning ON/OFF the robot

You can check the start/end status of your robot at present, and turn on or off the
robot.

 ON: Power up the motor for the robot joints and get ready for robot operation. If the
robot status is ON, then the OFF button will be activated and the ON button will be
deactivated.
 OFF: Power off the motor for the robot joints and enable robot operation. If the robot
status is OFF, then the ON button will be activated and the OFF button will be
deactivated.

Monitoring

 Program Name: Indicate the name of current program loaded.

 Program Auto Start: It is activated when setting the program auto start condition at
system startup Managing the Robot System Configuration. For details on the settings,
refer to 16.5 Managing the Robot System.

 Variable Monitoring: Displays the name and current value of the variable being used.

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Checking and setting the robot operation data

You can check the effective weight applied to the currently selected robot and quickly
retrieve the saved robot settings and program and apply them to the system.

 Reset: If the robot is malfunctioning or uncontrollable temporarily then initialize the

controller.
 Use safety limit check : Enables/disables menu’s safety settings.
 Active TCP: Indicates currently set TCP information.
 Load Robot Configuration: A user can load a robot configuration file exported to a
local storage. For more details about how to export robot settings, refer to 16.5 Managing
the Robot System Configuration .
 Tool Power(Voltage): Set the Power of Tool IO.
 Select Program File: You can select one of the program files stored in a local storage
and quickly apply it to the system.

Operating the robot

If you want to operate your robot according to the program selected in the operation
setting, then press the button in the preview window. For more details about the
preview screen, refer to 5.2 3D Preview Screen.

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If the current coordinates of the robot are different with the start coordinates of the
program, a pop-up window will be displayed for confirmation.

If there is an obstacle at the start of the current coordinate and there is a possibility of a
cllision, you can check it and move the robot to the safety position and start.

 Move: Move robot to start position.

 Manual: Manually move robot through the manual contro.
 Play: Start program from current position. If the robot is not at the start position of the
program, it moves to the start position and the program starts.
 Cancel : Cancel Playing program.

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Locking Screen
Restricts the operation of the screen during program execution. All operations except
screen lock button are restricted.

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Chapter 11 Monitoring

You can check the selected robot's position/status and I/O status in real time.

11.1 Monitoring the Robot

You can check the robot's position and status in real time.

Select Monitoring > Robot Status in the main menu.

Monitoring the robot positions

In the robot position tab, you can check the position of the selected robot (joint angle
and speed) and see how it is moving in real time in 3D preview.

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Checking the robot status

In the robot status tab, you can check the selected robot's power consumption, voltage
or current.

Note The monitoring values are displayed when the robot is running normally.

11.2 Monitoring Inputs/Outputs

You can check and set the real time I/O status of robot.

In the main menu, select Monitoring > I/O Status.

Note The monitoring period is 10 Hz.

 You can check the status of digital I/O by examining the following icons.

Digital signal high

Digital signal low
No signal

 The input terminals that users cannot adjust the values for and the output terminals that
users can adjust the values for are marked as follows.

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Input Output
terminal terminal

Monitoring controller inputs/outputs

In the I/O Status tab, the status of signals transmitted to and received from the I/O
terminal of the controller are displayed in real time.

 You can press the I/O status icons to switch digital outputs to high and low. For example,
if you press (High) then it switches to (Low).
 For analog outputs, you can press the icon to enter values.
- Voltage range: 0 ~ 10.00 V
- Current range: 0.004 ~ 0.02 A

 You can select either voltage or current as the analog I/O unit.

- : Voltage(V) is used.
- : Current(A) is used.

 If you change the unit of analog output, the output is changed to a minimum.

Note  The number of terminals may vary depending on the controller

specifications.
 If not all the terminals are displayed on the screen, press the
up/down scroll button to scroll them.

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Monitoring tool inputs/outputs

In the Tool I/O Status tab, the status of signals transmitted to and received from the
I/O terminal of the tool flange are displayed in real time.

 A tool's digital inputs/outputs and analog inputs are set and displayed in the same way
those of the controller are set and displayed.
 If you can set the output voltage to a tool, then you can select one from 0 V, 12 V, or 24 V.

Note  The value of the tool's current cannot be configured by the user.
 If the robot status is servo-off or the emergency stop button is pressed
to stop the robot, the monitoring screen may display abnormal
information.

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11.3 Utilization

You can check the robot's system operation time, servo start, and the program
operation time information.

Select Monitoring > Utilization in the main menu.

 Cumulative system operation time: Total cumulative system operation time from
production time to present

Note The basic unit for collecting the operation time is every hour; as such, there
may be error of up to one hour.

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Chapter 12 Device Settings

You can link your robot to an external equipment such as a PLC, a vision equipment
(object detection camera), and conveyor system.

Note Different external equipment is supported depending on the SW version.

12.1 Configuring MODBUS TCP

TCP based MODBUS is supported as an extended interface to communicate with

external devices such as PLCs. It is implemented in software and enables to set lots of
IOs.

From the main menu, select Robot Setting > MODBUS TCP.

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Registering Devices
To use MODBUS I/O, register a device to share I/O information with.

1. Press the Add button.

2. Enter following information in the Add Device screen and press the Add button.
 Device Name: Enter the device name to be displayed on the screen.
 IP Address: Enter the IP address of the device.
 Slave ID: Enter the slave ID of the device. Its input range is 0 to 255 in the
3-digit integer form.

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 Description: You may enter the description for the device. You can enter up
to 25 characters.

Editing/copying the device settings

You can modify settings for a device previously registered or copy the device settings to
use as settings for a new device. When copying, I/O information of the device is also
copied.

1. Press the Edit button from the list of registered devices.

2. Modify items you want to change and press the OK button. Or, press the Copy
button if you want to copy the device settings to use as settings for a new device.
 When you press the Copy button, the settings of the device currently selected
and information of I/Os under the device are also copied and added to the list.
The name of the newly created device is the name of the device copied from with
'_number' added.

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Deleting a device in the list

1. Select a device to delete from the list.

 Check the check box for the device.

2. Press the Delete button, and then press the OK button.

 When you delete a device, I/Os for the device will be deleted as well.

Registering I/O
After you registered a device, you must set an I/O or I/Os for it. The I/O(s) added is(are)
used to read a certain value from the device or to send HCR status values to it.

The type of I/Os for the MODBUS are as follows:

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 Digital Input: Reads digital values (High/Low) from a device.

 Digital Output: Sends digital values (High/Low) to a device.
 Register Input: Reads 2-byte values (0-65535) from a device.
 Register Output: Sends 2-byte values (0-65535) to a device.

1. Select a device to add an I/O to from the device list.

 When a device is selected, I/Os currently added to it are displayed.

2. Press the Add button.

3. Enter information of the I/O and press the OK button.

 Name: Enter the user identifiable name of the I/O.
 Signal Address: Enter the pre-defined address to be used for the I/O.
 Type: Select Digital I/O or Register I/O.
 Frequency: Select the frequency of data transmission for the I/O. Available
frequency values are 0, 1, 2, 5 and 10.

Note You can use I/Os when you make a program. Especially, you can use
register-type I/Os as variables in a program.

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Viewing the communication status

After an I/O is registered, you can view its communication status.

Normal
Unable to connect
Input value error
Device response delay
Address error

Viewing and setting the I/O values

After an I/O is registered, you can view or set its value.

 Digital Input: Indicates an icon for the digital value (High/Low) currently being input.
- : High
- : Low

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 Digital Output: Indicates an icon for the digital value (High/Low) currently being output.
Press the value to change it.
- : High
- : Low

 Register Input: Indicates the value currently read from the device.
 Register Output: Indicates the value being currently sent to the device. Press the value to
change it.

Editing I/O settings

1. Press the Edit button of an I/O to be modified from the I/O list.

2. Modify the settings and press the OK button.

Note It is not allowed to change the I/O type. To change the type, you must
delete the I/O setting and add it again.

Deleting I/O

1. Select an I/O to delete from the I/O list.

2. Press the Delete icon.

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12.2 Using a Vision System

You can register the vision to be linked to the robot and configure necessary settings.

In the main menu, press Device Setting > Vision System.

To interwork with the vision, the following two steps are required.

 Vision System Setting

- Communication Setting: To send and receive data to and from the vision
system, data is exchanged via TCP/IP communication. The vision system
should be set up to use TCP/IP communication.

- Exchange Data Format (Protocol) Setting: To exchange data with the robot
system, the type and format of the data sent from the vision system should be
set as follows.

 Data Communication Protocol

The data format consists of a string, which is set up to be transmitted by the

vision system in the following conventions.

TJG , X , Y , TH CR LF

TJG: Result value from object recognition in the vision. 1(Success) or 0(Fail)
X: X coordinate value of object recognized by the vision
Y: Y coordinate value of object recognized by the vision
TH: Rotation theta value of object recognized by the vision
CR, LF: Separator for the end of data
Comma(,): Separator for each item

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 Robot System Setting

- Interworking vision setting: Sets the model and communication connection

information of the vision to be interworked.

- Vision workspace setting: One vision camera can have a number of vision
work areas, and by using the information set by the 'Vision workspace setting,'
the vision coordinates recognized by the vision are converted into the robot
coordinates to move the robot.

12.3 Adding and setting vision equipment

Adding a vision equipment

Press the Add button. They will be added under names such as Vision1, Vision2 to the
list and they become configurable.

Setting a vision equipment

 Name: Enter the equipment name. (The length of name is limited to 15 letters and
special characters cannot be used.)
 Model: Select the manufacturer for your vision equipment.
- Omron vision
- Cognex vision
- Hostar vision
- Keyence vision
- Baumer vision

Note Different vision equipment is supported depending on the software

version.

 Connection info: Enter the TCP/IP address and the port number necessary for
communication between a vision equipment and the robot.
- Range of port number: 0 ~ 65535
- Press the Connection Test button to check the status of connection with a vision
equipment by using the connection data.

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Note To perform the connection test correctly, the vision system and our system
must be connected to a single network before the test.

 Vision Type: Select a type of vision installation.

- Embedded: Attached to the robot arm.
- Stand Alone: Fixed to another location and detached from the robot arm.

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12.4 Setting Vision Workspace

Vision workspace setting sets information to change the vision coordinate recognized
by the vision to the robot coordinates. Up to 5 workspaces can be set for one vision.

Adding Vision Workspace

 To add a vision workspace, select the vision already added from
the vision list.
 When you click the Add vision workspace button, the following workspace
setting screen appears.

 Name : Enter a name for the vision workspace. The input range is up to 15
characters, and no special characters are allowed. (Exclude '-' and '_'.)
 Vision Scan Coordinates: If the vision type is Embedded, the setting is
necessary for moving the robot arm to the scanning location.
- Press the Move button to move the robot arm to desired location and view it
there.
- Press the Set Point button to launch the manual control screen. For more details
about the manual control screen, refer to 5.3 Manual Move Screen.

 Rotation Offset: If the vision type is Stand Alone, you can set the angle
between the robot's location and the scanning location, so that the rotational angle
for an object necessary for a gripper to hold it. Press the Set Offset button to
automatically set the rotation offset. For more details, refer to the next page.

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 Vision Test: Test vision with the set values.

 Set Points: It matches the number of guide image and is activated by clicking the
number. The initial value is ‘0’. At each number, enter the robot coordinate values
and the coordinates of the vision system at that point. Range :
-10000~10000(Pixel)
 Rotation Direction Setting: Sets the rotation direction of the object recognized
by the vision.

Note When attaching the vision to the robot arm, attach the upper left /
upper right / lower right directions shown on the setup screen so that
they match the directions shown in the vision software.

Understanding rotation offsets

When a vision equipment scans an object, the angle of shifted position for an object is
used the reference for a vision equipment. Thus, the angle data of object that a vision
equipment sends to the robot is obtained from the perspectives of vision equipment.
Now, if the robot does not know the angle between the scanning location and the its
position (rotation offset), then the robot will assess the scanned angle data from its own
perspectives and use a gripper accordingly, thus making it hard to pick up an object
accurately.

As shown below, if the scanning location is same as the basic TCP location of robot (A)
all it has to do is to rotate the gripper angle by as much as the angle of scanned object.
However, if the scanning location is shifted by X degrees from the robot base, then
when an object is scanned, although a vision equipment detects the angle of object as
same as from the location (A), its gripper will have to rotate by X degrees to pick it up.
In other words, from the robot's perspectives, it is same as if an object is shifted by X
degrees, so, a rotation offset is required to compensate for the angle of object sent from
a vision equipment.

A. When the scanning location and the robot's location are on the same line

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B. When the scanning location and the robot's location are shifted by X°

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Chapter 13 Environment Setting

13.1 General Setting

You can select the desired UI language and unit also set the time/date.

In the main menu, press SW Configuration > General.

 Language Selection: You can select a language for the UI.

 Units Selection: You can select units of weight.
 Date & time settings: You can set the system date/time.
 Calibrate Touch Screen: If it is hard to touch a desired location on the screen, then
you can correct the touch locations.

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Note The language and unit settings are immediately applied to the system
without restarting it, but the time/date are applied to the system after
restarting it.

13.2 Network setting

You can configure the network settings for Ethernet communication of your operation
software.

In the main menu, press SW Configuration > Network.

 DHCP: IP address is automatically assigned.

 Static IP: Fixed IP address is used.
 Obtain DNS server address automatically: DNS address is automatically
received.
 Use following DNS server address: Use the DNS server designated by the user.
 Do not use: Do not connect to the network. Use it as standalone.

Note For more details about network settings, consult with your system network
administrator.

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Chapter 14 Turning Off the System

14.1 Shutting Down the Operation Software

To shut down the operation software, proceed as follows.

1. Select SW Configuration > Shutdown in the main menu.

2. Press the OK button.

Note  You can press the power button of the teaching pendant to shut it
down.
 If the operation software does not shut down properly, press and hold
the power button of the teaching pendant for 5 to 10 seconds.

Caution
Shutting down the system improperly may cause problems for the software.
If the software has a problem after abnormal system termination due to the reason
that the system is forcefully turned off by the power switch or the Power button of
TP, or the power is out, contact local distributor.

14.2 Turning Off Controllers

After shutting down the operation software, press the power switch to turn off the
controller.

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Chapter 15 Maintenance

15.1 Inspection Items and Periods

Periodic inspections are required to maintain the robot in the best condition for a long
period of time. An inspector should prepare and execute an inspection plan.

The following items require periodic inspections. If you found some problems during
inspections, and you can resolve them on your own, contact Hanwha Precision
Machinery Co.

Inspection item What to inspect Periods

Check if the robot moves to the desired
All Daily
destination according to the program.

All Remove stains, dusts and pollutants. 3 months

Check if the robot arm or tool sags when you

Robot All Daily
turn on/off the servo power.
arm
Main Check if the bolts exposed to the outside of
3 months
bolts the robot is loose.

Check for abnormal heat generation or

Motor Daily
noises.

Cable Check the cable connections.

Controller Internal Remove dusts from the inside. 6 months

Filter Remove dusts from the filter.

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15.2 Checking the Robot Arm

Inspection period
Inspect at least once every 6 months. The inspection period may vary depending on the
inspection area.

Checking and cleaning the robot arm

1. Move the robot arm to home.

2. Turn on the controller.

3. Check the followings.

 Check the cable connecting the controller and the robot arm.
 Check if the screws exposed outside is loose or unfastened.
 Check for defects in the motor, the brake and the decelerator.

4. Remove stains, dusts and pollutants.

15.3 Checking the Controller

If dusts accumulate inside the controller, electrostatics or overheating can cause product
malfunctions. Periodically check the inside of the controller and clean off dusts and
check if the internal cables are connected properly.

Inspection period
Inspect at least once every six months.

Note The inspection periods may vary depending on the installation

environment.

Checking and cleaning the controller

1. Turn off the power for the controller.

2. Open the cover for the controller.

3. Check if there are dusts inside the controller.

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4. If there are dusts, then use a vacuum cleaner to carefully remove dusts.

5. Check if the connector cables are connected properly.

Cleaning and replacing the filter

The controller has an air suction hole and an air discharge hole, which have dust filter
mounted in them.

Separate the filter from the controller and use a vacuum cleaner or air compressor to
remove dusts.

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15.4 Viewing and Managing Logs

You can view and manage the logs for the operation system.

Select Management > Log in the main menu.

Deleting Logs

Press the Delete button and the log data found will be deleted.

Exporting Logs

1. Press the Export button.

2. Select the location to export the logs into and press the OK button.

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When export is finished, a folder in the form of 'date-time' is created at the selected
location, and the log data are saved in the folder along with the robot configuration and
program files.

15.5 Managing the Robot System Configuration

You can save the robot configuration in a local or external storage device or retrieve the
saved robot configuration from them.

In the main menu, select Management > Setting Management.

Packaging posture
 Arrange the posture of the robot in a position that allows it to be placed in the delivery
box.
 The robot only operates while the button is pressed.
 The posture depends on the model of the target robot.
[ J1:0, J2:-90, J3:-160, J4:-90, J5:180, J6:0 ]

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Factory reset
 Initializes the system to its factory settings.
 A warning message is displayed twice before the reset is performed.
When the factory reset is complete, the system restarts.

Note If you perform a factory reset, all information including the robot
information will be deleted. Please back up the necessary information
before you perform a reset.

Use Default Program

Set the program and configuration file to load automatically when the robot is booted.
It provides Servo On and program start function automatically after booting.

 Check Use Default Program to activate it.

 Select the program to be loaded among the stored programs.
 Set the condition of Auto Start Program on System Startup.
 Select Initial Setup File to use among the saved configuration files.
 Set the condition of Auto Servo.

Note The available inputs are Digital Input or Digital Input of Modbus TCP.

Exporting the configurations

You can save the following settings by exporting them.

TCP Setup
Robot Setting
Mounting

Motion Limit
Safety Setting
Safety Boundary

Digital I/O
I/O Setup
Analog I/O

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1. Select the file path to export.

 Press the refresh button to update the storage list and the file list.

2. Press the filename input field and enter the filename.

 Filename is limited to 25 letters, and empty character is not allowed.

3. Press the Export button.

4. When the confirmation window appears, press YES.

Importing the configurations

1. Select the file path for importing.

 Press the refresh button to update the storage list and the file list.

2. Press the Import button.

3. Select the configuration items to import and press the OK button.

 You can select multiple items.
 If you want to deselect it, press it again.

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4. When the confirmation window appears, press YES.

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15.6 Software Update

You can update the software.

In the main menu, press SW Configuration > SW Update.

Cautions during update

 Update can be performed using the external storage device only.(The USB memory
may not be compatible depending on the manufacturer)

 If you connect a USB drive to TP, as there is a lot of data, the operating software
may not be updated normally. Be sure to connect directly to the controller.

 Update files may be composed of multiple files instead of a single file. For proper
update of files, do not modify the name or path of an update file package arbitrarily.

 The update function is not available for general users but for the user with a certain
authority. If you need an update, contact Hanwha Precision Machinery or a local
service center.

Updating software
Check the version of the software and proceed as follows:

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1. Connect the external storage device (such as the USB memory) where the update
files are stored to the USB port of the teaching pendant or the controller.

2. In the software update screen, press the Import button.

3. Select an update file in the correct location and press the OK button.
 The extension of the update file is "tgos", and the update file name contains its
version. The file selection window displays applicable files only.

4. From the software update window, press the Update button.

When the software is updated, the system restarts.

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 Appendix A Warranty

Refer to the contract between the sales team and you.

Warranty
Our company guarantees specifications, quality and reliability that our customer
demands during the warranty period.

Warranty period
One year since the date of equipment purchase (varies depending on the contract
between our company and you.)

Limitation of Liability
 If a problem occurs after the customer mounts an unauthentic part in our product, our
company will not be responsible for it.

 If your product has a fault deemed as our company's responsibility, we will immediately
repair it or replace the product with a good one.

191
 Appendix B Certification

Safety

192
193
 MD(Machinery Directive)

194
LVD(Low Voltage Directive)

195
 EMC (Electro Magnetic Compatibility)

196
Cleanroom-Body

197
 Cleanroom-Controller

198
Appendix C Dimensions for Installation

199
 Appendix D Tool Flange Cross Section

The tool flange is designed suitable for ISO9409-1-50-4-M6.

200
 Appendix E Port Pin Map

Ports in the tool flange have the following specifications.

 Tool I/O: SACC-DSI-M12FS-12CON-M16/2,0 – 1458790

 EtherCAT: SACC-DSI-MSD-4CON-M12/0,5 SCO – 1551901

Port Layout Pin number Signal Color

1 0/12/24 Vdc Brown

2 Ground Blue

3 Digital Output Ch 0 White

4 Digital Output Ch 1 Green

5 Digital Output Ch 2 Pink

6 Digital Output Ch 3 Yellow

Tool I/O
7 Digital Input Ch 0 Black

8 Digital Input Ch 1 Gray

9 Digital Input Ch 2 Red

10 Digital Input Ch 3 Violet

11 Analog Input Ch 0 Gray/Pink

12 Analog Input Ch 1 Red/Blue

1 TX+ Red

2 RX+ White
EtherCAT
3 TX- Orange

4 RX- Blue

201
 Appendix F System Specifications

Degree of freedom 6

Base weight 5 kg

Working radius 915 mm

Joint rage ±360°(J3: ±165°)

Repeatability ±0.1 mm

Weight 20 kg

Bottom area size Ø150 mm

Temperature 0 – 50°

IP class IP54 (Robot Arm) / IP20 (Robot Controller)

Power supply 100 – 240 VAC, 50 – 60 Hz

Controller Tool connector

I/O port Digital input 16 4

Digital output 16 4

Analog input 2 2

Analog output 2 -

EtherCAT - 1

I/O power supply Controller: 24 V 2 A

Tool connector: 12 V or 24 V 1.6 A

External communication TCP/IP, Modbus TCP,

CC-link / Profinet / Ethernet / IP (Gateway required)

Cable length Robot arm to controller connection cable: 6 m

Teaching pendant to controller connection cable: 5 m

202
Appendix G Stopping Time and Distance

Stopping time and distance for stop category 1

The robot configuration to measure the stopping time and the stopping distance for the
stop category 1 is as follows:

 Position: Maximum load position (the position of the robot arm fully stretched
horizontally to make the maximum load)

 Speed: Maximum joint speed (maximum speed of 180°/sec which can be generated
at the robot joint)
 Payload: Maximum load possible to be installed on the TCP (5 kg)

The behavior to measure the stopping distance for the joint J1 was driven in parallel to
the ground and joints J2 and J3 were driven perpendicular to the ground. The stop
category 0 was performed when each joint reached its maximum speed.

It takes 0.03 sec for the brake to be engaged for deceleration after the stop signal is
detected.

Stopping Distance (deg.) Stopping Time (sec.)

Joint J1 34.67 0.61

Joint J2 31.60 0.55

Joint J3 29.08 0.51

Speed (deg/s)

Maximum Joint
Speed
(180 deg/s)

Time (s)
0.0 30 Maximum Stopping Time

203
 Stopping time for stop category 1
The robot configuration to measure the stopping time for the stop category 1 is as
follows:

 Position: Maximum load position (the position of the robot arm fully stretched
horizontally to make the maximum load)

 Speed: Maximum joint speed (maximum speed of 180°/sec which can be generated
at the robot joint)
 Payload: Maximum load possible to be installed on the TCP (5 kg)

Create a behavior to stop regardless of the speed and the payload so that it comes to a
full stop after a certain period (0.250sec).

204
Hanwha Address Hanwha Precision Machinery R&D Center, 6, Pangyo-ro 319
Precision beon-gil, Bundang-gu, Seongnam-si, Gyeonggi-do (13488),
Machinery Republic of Korea
Co., Ltd. Email robot_inquiry@[Link]
Homepage [Link]
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