Doosan M0609 User manual

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Doosan Robotics Installation Manual v1.3
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Table of Contents
Preface..................................................................................................7
Copyright.......................................................................................................................7
Information about open source software (OSS) licensing...................................7
How to read this manual.............................................................................................8
1. Safety...............................................................................................9
Icons used in this manual...........................................................................................9
1.1 Safetyicons..........................................................................................................9
1.2 General precautions..........................................................................................11
1.3 Purpose of the product.....................................................................................13
1.4 Riskassessment...............................................................................................14
1.5 Potential risks.....................................................................................................16
1.6 Validityand responsibilities ............................................................................17
2. Exploring the Product................................................................ 18
2.1 Components.......................................................................................................18
2.2 Name ofparts and their functions..................................................................19
2.2.1 Robot.............................................................................................................................................................................. 19
2.2.2 Controlbox.................................................................................................................................................................... 21
2.2.3 Teachpendant............................................................................................................................................................. 22
2.3 System architecture..........................................................................................23
2.4 General product specifications.......................................................................23
2.5 Robotspecifications.........................................................................................24
2.5.1 Basicspecifications..................................................................................................................................................... 24
2.5.2 Axis-specificspecifications........................................................................................................................................ 24
2.5.3 Operatingradiusoftherobot.................................................................................................................................... 24

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2.5.4 Max.payloadwithintheoperatingradius............................................................................................................. 27
2.5.5 Toolcenterposition..................................................................................................................................................... 28
2.6 Labels..................................................................................................................28
3. Installing the Robot.................................................................... 30
3.1 Installationprecautions....................................................................................30
3.2 Installationenvironment...................................................................................30
3.2.1 Installationlocations..................................................................................................................................................... 30
3.2.2 Checkingtherobot'soperatingradius................................................................................................................... 32
3.3 Hardware installation........................................................................................35
3.3.1 Fixatingtherobot.......................................................................................................................................................... 35
3.3.2 Connectingatooltotherobot.................................................................................................................................. 37
3.3.3 Connectingtherobottothecontrolbox................................................................................................................ 39
3.3.4 Connectingthecontrolboxtotheteachpendant.............................................................................................. 42
3.3.5 Pluggingtherobotintothecontrolbox................................................................................................................... 44
4. Interfaces..................................................................................... 46
4.1 Flange I/O............................................................................................................46
4.1.1 Flangedigitaloutputspecifications.......................................................................................................................... 48
4.1.2 Flangedigitalinputspecification............................................................................................................................... 49
4.2 Control box I/O connections...........................................................................51
4.2.1 Configuringthesafetycontactinputterminalblock(TBSFT).......................................................................... 52
4.2.2 Configuringthesafetycontactoutputterminalblock(TBSTO)...................................................................... 53
4.2.3 ConfiguringthedigitalI/Opowerterminalblock(TBPWR)............................................................................. 54
4.2.4 ConfiguringtheconfigurabledigitalI/Oblocks(TBCI1-4andTBCO1-4)................................................... 55
4.2.5 ConfiguringtheanalogI/Oterminalblock(TBAIO)........................................................................................... 62
4.2.6 EncoderInputTerminal(TBEN1,TBEN2)Configuration.............................................................................. 64
4.3 Connecting to a network..................................................................................67
4.3.1 Connectingtoanexternaldevice–Visionsensor............................................................................................. 68
4.3.2 ModbusTCPSlaveSetup........................................................................................................................................ 68

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4.3.3 ExpandedProtocol-PROFINETIODevice(PNIOdevice)Setup............................................................ 69
4.3.4 ExpandedProtocol-EtherNet/IPAdapter(EIPadapter)Setup................................................................... 69
4.3.5 UsingExpandedProtocol......................................................................................................................................... 69
4.3.6 UsingGeneralPurposeRegister(GPR)............................................................................................................. 69
5. Robot Mode and Status............................................................. 71
5.1 ManualMode......................................................................................................71
5.2 Auto Mode...........................................................................................................71
5.3 Status and Flange LED Color for Each Mode..............................................71
6. Safety-related Features............................................................. 74
6.1 Introduction........................................................................................................74
6.2 Safety-Rated Stop Function ............................................................................74
6.2.1 Emergencystopfeature............................................................................................................................................ 75
6.2.2 ProtectiveStop............................................................................................................................................................. 76
6.3 Safety Rated Monitoring Function.................................................................76
6.4 Safety-Rated IO..................................................................................................77
7. Transporting the Robot............................................................. 78
7.1 Precautions when transporting the robot.....................................................78
7.2 Pose for the robot’s transportation................................................................78
7.3 Packaging boxspecifications.........................................................................78
8. Maintenance................................................................................ 80
9. Disposal and Environment ....................................................... 81
10.Product Warranty and Liability................................................ 82

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10.1 Scope ofwarranty.............................................................................................82
10.2 Warranty limitations and exceptions.............................................................82
10.3 Transfer...............................................................................................................83
11.Product Certification.................................................................. 84
11.1 Third party certification....................................................................................84
12.Disclaimer.................................................................................... 85
Appendix A: System Specifications ............................................. 86
12.1 Robots.................................................................................................................86
11.1.1M0609................................................................................................................................................................................. 86
11.1.2M0617................................................................................................................................................................................. 87
11.1.3M1013................................................................................................................................................................................. 87
11.1.4M1509................................................................................................................................................................................. 88
12.2 Control box.........................................................................................................89
12.3 Teach pendant...................................................................................................90
Appendix B: Certification ............................................................... 91
CE (MachineryDirective)..................................................................................91
CE (Electro Magnetic Compatibility Directive).............................................92
NRTL (US, CANADA)........................................................................................93
VoluntarySafetyCertification (KCs)..............................................................94
Declaration ofIncorporation............................................................................98
Functional SafetyCertificate...........................................................................99
Annex C Stop Distance and Stop Time...................................... 100
C.1 Measurement Methods and Conditions........................................................100

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C.2 M1013..................................................................................................................100
C.3 M0609..................................................................................................................103
C.4 M0617..................................................................................................................106
C.5 M1509..................................................................................................................109

Table of Contents
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Preface
Thank you for purchasing Doosan Robotics' product. Please read this manual thoroughly before
installing the product and follow the instructions in the manual when installing it. The content o
f this manual refers to the latest product versions at the time of writing, and the product inform
ation provided in the manual is subject to change without prior notice to the user.
Copyright
Doosan Robotics has copyright and intellectual property rights to all content and all designs sho
wn in this manual. Therefore, any use, copying, or dissemination of them without written permis
sion from Doosan Robotics is prohibited. Please note that you will be held solely responsible fo
r any improper use or alteration of the patent rights of Doosan Robotics.
This manual provides reliable information. However, we are not responsible for any loss or dam
age arising from errors, typos, or omissions in the manual. The information contained in this m
anual may change without prior notice due to product improvements.
For further information on the revision details, please visit the Doosan Robotics website (www.d
oosanrobotics.com).
© 2018 Doosan Robotics Inc., All rights reserved
Information about open source software (OSS) licensing
The software that comes with the product is free and open source.
For more information about the licensing of free and open source software, please see the OS
S usage notice page on our website (www.doosanrobotics.com/kr/oss/license)
If you have any questions regarding this matter, please contact Doosan Robotics’ Marketing De
partment at [email protected].

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How to read this manual
This manual contains comprehensive information necessary for using the product, from how to i
nstall the robot to how to use programming features. Each version of the manual consists of th
e following:
•User Manual: Provides information on how to install the robot mechanically and electrically,
as well as information on how to use the robot and how to manage its tasks.
•Programming Guide: Provides information on the programming languages used to control t
he robot.

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1. Safety
This chapter provides safety information that you must acquaint yourself with before installing or
using the robot. All robots have risks associated with high voltage, electricity, and collisions. T
herefore, you must observe basic safety precautions when using the robot or its parts in order
to reduce the risk of personal injury and of damage to the machine. These safety precautions
are designed to ensure your safety and prevent damage to your property, so please read them
carefully in order to use the machine correctly.
Icons used in this manual
The following icons are used in this manual in order for you to take proper safety precautions
when using the product: The specifications and content of the user manual may change for the
purpose of product improvement and performance enhancement.
Icon
Name
Description
Danger
Failure to observe the instructions indicated by this icon may
lead to serious accidents and may also cause serious injury or
death to the worker.
Warning
Failure to observe the instructions indicated by this icon may
lead to accidents and may also cause serious injury to the
worker.
Caution
Failure to observe the instructions indicated by this icon may
cause damage to the product and injury to the worker.
Note
Additional information helpful to you.
1.1 Safety icons
The following are the icons related to safety among the icons used in this manual:
Icon
Description
Danger
Indicates that an electrically hazardous situation can happen anytime soon due to
high voltage, etc. Failure to observe the instructions indicated by this icon may lead
to serious accidents and may also cause serious injury or death to the worker.
Danger
Indicates that a hazardous situation can happen anytime soon. Failure to observe
the instructions indicated by this icon may lead to serious accidents and may also
cause serious injury or death to the worker.
Warning
Indicates that an electrically hazardous situation can happen due to high voltage,
etc. Failure to observe the instructions indicated by this icon may lead to accidents
and may also cause serious injury to the worker.

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Icon
Description
Warning
Indicates that a hazardous situation can potentially happen. Failure to observe the
instructions indicated by this icon may lead to accidents and may also cause serious
injury to the worker.
Caution
Indicates that a hazardous situation can potentially happen due to overheating.
Failure to observe the instructions indicated by this icon may lead to accidents and
may also cause serious injury to the worker.
Caution
Indicates that there is a likelihood of damage to the product or of injury to the
worker.

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1.2 General precautions
This chapter describes general Danger and Warning situations that can arise during the use of
the robot.
•Make sure to install the robot and other electric devices by consulting the installation man
ual.
•If you intend to mount a device onto the tool when installing the robot, fixate the device u
sing appropriate bolts.
•When installing the robot, you must install proper safety measures such as a safety barrier
to protect the worker and the operator of the robot.
•Do not wear loose clothing or jewelry when using the robot. If your hair is long, tie it bac
k so that it does not get caught between the robot's joints, etc.
•Never operate damaged robots.
•Pay attention to the movement of the robot when using the teach pendant.
•If the teach pendant warns of a fatal error, immediately turn on the robot’s emergency sto
p switch to cease the operation of the robot. Afterwards, identify the cause, eliminate the f
atal error, and then operate the robot again. If you cannot eliminate the fatal error by your
self, contact your dealer or robot supplier.
•Make sure to interface safety devices to the machine via safety contacts. Doing so via ge
neral purpose interface contacts may not guarantee the functioning of safety features.
•Make sure to read and understand the User Manual for the robot before operating it.
•If the robot collides with an external object, a considerable level of shock may be generat
ed. The level of shock that the robot receives is proportional to its kinetic energy. Therefor
e, when the robot is operating at high speeds with a large payload, the level of the resulti
ng shock can be huge. Make sure to drive the robot at safe speeds with a safe payload
volume in collaborative spaces.
•The direct teaching feature must be used in a safe environment. Do not use the direct tea
ching feature when there are sharp objects in the surrounding areas or when there is a lik
elihood of the tool getting stuck in other objects.
•Make sure to enter the relevant specifics (tool length, weight, center of gravity, etc.) correc
tly before using the direct teaching feature. If the actual tool's specifications and the entere
d specifics do not match, the direct teaching feature may fail or malfunction.
•To ensure user safety, joints will be operated at a constant speed or the maximum speedo
f the TCP may be limited during direct teaching. If the limit is exceeded, the protective sto
p function activates.
Warning
Warning

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•Enable/disable the direct teaching feature only when the robot has completely stopped. Acti
vating/deactivating the direct teaching feature while the robot is running may cause malfunc
tion of the robot.
•When the robot won’t operate, and when the robot's shaft needs to be turned manually, y
ou can turn the shaft by applying a torque of 400 Nm or more to it.
•Modifying the robot without permission can result in critical failures and serious accidents.
•The robot and controller generate heat when used for an extended period of time. Do not
touch the robot with your hand after using it for an extended period of time. If it is necess
ary to touch the robot with your hand to perform tasks such as installing a tool, turn off th
e power to the controller and leave the robot for more than 1 hour for it to cool down bef
ore performing such tasks.
•Do not expose the robot to strong magnetic fields. Doing so may damage the robot. .
Caution
Caution

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1.3 Purpose of the product
This product can be used for industrial purposes: to fixate products and their components and
move objects with the intention of transferring or assembling them by means of its tool. It must
only be used in the environments specified in its specifications.
This product contains special safety features for the purpose of collaborating with people and w
orks with people without a border. Be sure to perform any task using the system only after all
applications - including the tool, work object, perimeter, and other equipment - have been deter
mined to be non-hazardous in a risk assessment.
Using the product for purposes other than intended, as enumerated below, shall be considered i
mproper use. Doosan Robotics shall not be liable for any damage to and malfunction of the ro
bot or any damage to the user's property and personal injury resulting from improper use of th
e product.
•Using the product in potentially explosive atmospheres
•Using the product for medical- and life-related applications
•Using the product to transport people or animals
•Using the product without a risk assessment
•Using the product where the performance and environmental requirements have not been
met.
•Using the product when the performance of its safety features is inadequate
•Using the robot to stand on it
•Using the product where higher levels of electromagnetic radiation than international IEC st
andards are emitted, as in a welding process

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1.4 Risk assessment
One of the most important factors for system integrators is risk assessment. Risk assessment is
a legal requirement in most countries. In addition, because a safety assessment of a robot ins
tallation depends on how the robot integrates into the whole system, a risk assessment cannot
be performed solely with the robot itself.
In order to be able to carry out a risk assessment of a robot, the administrator responsible for
establishing the whole system must install and operate the robot in accordance with the guideli
nes of ISO12100 and ISO10218-2. In addition, the administrator can also perform the procedure
by consulting technical specification ISO/TS 15066.
Risk assessment should consider the entire work process in relation to the total lifespan of the
robot application. The main objectives of risk assessment are:
•Setting for the use of the robot and teaching the robot's tasks
•Problem diagnostics and product maintenance
•Ensuring the robot is properly installed
Make sure to perform a risk assessment before turning on the power to the robot arm for the f
irst time. Establishing the right safety configuration and identifying the need for additional emerg
ency stop buttons and other protective measures for specific robotic applications are part of a ri
sk assessment.
Figuring out the right safety configuration is a particularly important part of developing collaborat
ive robotic applications. For more information, refer to the corresponding section in the manual.
Some safety-related features are designed specifically for collaborative robotic applications. Thes
e features can be configured through Safety Configuration and are particularly suited to address
ing the specific risks identified in the risk assessment performed by the system integrator.
The safety-related features for the collaborative robot can be configured in the Safety Configurat
ion section and provide the following functions:
•Force and power limiting: Limits the robot’s stopping force and pressure in case the robot
and the worker collide.
•Momentum limiting: Limits the energy and impact load generated upon a collision of the ro
bot and the worker by decreasing the speed of the robot.
•Joint position and TCP limiting: Limits the robot's movement so that it does not move towa
rds specific body parts of the user, such as the neck and head
•TCP and tool pose limiting: Sets limitations to reduce risks associated with specific areas
or features of the tool or workpiece (e.g., preventing sharp edges of the tool or workpiece
from moving towards the worker)
•Speed limiting: Lets the robot maintain a low operating speed to give the worker enough ti
me to avoid a collision with the robot.
Applying the right safety configuration is considered equivalent to locking the robot in a specific
position and connecting it to a safety-related IO. For example, the system integrator can preve
nt unauthorized persons from changing the robot’s safety configuration by using features such a
s password protection.
Particularly important when evaluating risk in collaborative robotic applications are:
•Severity of each individual potential collision

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•Likelihood of occurrence of each individual potential collision
•Likelihood of avoiding each individual potential collision
If the robot has been installed into a non-collaborative robot application where it is not possibl
e to eliminate risks (e.g. when using a dangerous tool) in a reasonable or adequate manner us
ing built-in safety features, the system integrator must conclude in the risk assessment that prot
ective devices should be added to the system (e.g., using devices that protect the integrator du
ring installation and programming).

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1.5 Potential risks
•The robot system manufacturer must establish additional protection measures if the robot’s
built-in safety features are found to be incapable of sufficiently reducing the risk on their
own. The robot system manufacturer’s administrator must consider the following potential ri
sks. Please note that risks other than those listed below can also arise, and to prevent th
at, you must perform a risk assessment before using the product. Fingers getting caught b
etween the robot base and the mounting base
•Body getting caught between the upper arm and lower arm (joint 3 (J3) and joint 4 (J4))
•Body getting caught between the wrist and the shoulder (joints 1 and 2 (J1, J2) and joints
5 and 6 (J5, J6))
•Sharp edge or area of the tool penetrating the skin
•Sharp edge or area of an obstructive object adjacent to the robot’s operating area penetrat
ing the skin
•Sustaining bruises due to the robot’s movement
•Bone fracture due to the robot’s movement between a heavy payload and a solid surface
•Consequences of the loosening of the bolts securing the robot arm and the tool
•Object dropping from the tool due to an incorrect grasp or abrupt power loss.
•Consequences of mistakenly pressing the emergency stop button of another apparatus.
•Errors due to unauthorized change of safety configuration parameter values

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1.6 Validity and responsibilities
This manual does not cover information on how to design, install, and operate robot application
s integrated with other systems. In addition, it also does not cover information about peripherals
that can affect the safety of the integrated system.
The system administrator must comply with the safety requirements demanded by the national s
tandards and regulations of the country where the robot is to be installed. In addition, the pers
on responsible for integrating the robot into the system and managing it must ensure that the a
pplicable national safety laws and regulations are observed. The person implementing the final r
obot-applied system and the user have the following responsibilities, but the scope of their resp
onsibilities are not limited to them:
•Assessing risks in the system into which the robot has been integrated
•Adding and removing safety devices according to the risk assessment results
•Verifying that the system has been properly designed, configured, and installed
•Establishing a standardized way of using the system and related guidelines
•Managing suitable safety configurations in the software.
•Preventing the user from changing the connected safety devices
•Testing the validity of the design and installation of the integrated system
•Specifying important markings or contacts regarding safety and the use of the product
•Providing technical documents such as manuals
•Providing information on applicable standards and laws http://doosanrobotics.com/support/
Observing the safety instructions in this manual does not guarantee that you can avoid all pote
ntial risks.

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2. Exploring the Product
2.1 Components
Robot
Control Box
Teach Pendant
Control Box Power Cable
Robot Connection Cable
User Manual
Note
 The product’s components may vary depending on the robot model.

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2.2 Name of parts and their functions
2.2.1 Robot
Name of parts
No.
Part
No.
Part
1
Tool Flange
6
J3
2
J6
7
Link1
3
J5
8
J2
4
Link2
9
J1
5
J4
10
Base
10
2
9
8
1
4
6
5
7
3

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Main function
Part
No.
Description
1
Tool Flange
The area on which a tool is mounted
2
Flange I/O(2ea)
The I/O port for tool control (digital input 3ch, output 3ch)
3
LED
Displays the status of the robot
4
Cockpit (teach
button)
The button used to perform direct teaching (optional)
5
Connector
Used for the robot’s power supply and communication.
1
2
4
3
5