fruitcore robotics HORST900 User manual

87
Robot System HORST900
Assembly Instructions
For installation, operating, and maintenance personnel
Always keep with the product!
Version 3.1 / 09.02.2022

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Copyright
© by fruitcore robotics GmbH
fruitcore robotics GmbH claims copyright protection for these documents.
Original language of the documentation: German
This documentation must not be altered, expanded, reproduced, or passed on to third parties without the
previous written consent of fruitcore robotics GmbH.
fruitcore robotics GmbH
Macairestr. 3
78467 Konstanz, Germany
Telephone: (+)49 (0)7531 / 945 99-20
Email: [e-mail]
Website: www.fruitcore-robotics.com
Date of issue: February 2022
Subject to design and machine alterations

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IV
Contents
1Introduction................................................................................................................. 1
1.1 Principle........................................................................................................................................... 1
1.2 General Information ...................................................................................................................... 1
1.3 Operating Responsibility and Liability........................................................................................ 1
1.3.1 Legal Disclaimer............................................................................................................ 2
1.4 Warranty.......................................................................................................................................... 2
1.5 Organizational Measures ............................................................................................................. 2
1.6 Applied Standards and Regulations........................................................................................... 2
1.7 Signs, symbols ............................................................................................................................... 3
1.8 Marking of the Safety and Warning Signs ................................................................................ 3
2Safety............................................................................................................................ 5
2.1 General Safety Information.......................................................................................................... 5
2.2 Proper Use ...................................................................................................................................... 5
2.3 Improper Use.................................................................................................................................. 6
2.3.1 Foreseeable Misuse...................................................................................................... 6
2.4 Operator’s Duties ........................................................................................................................... 7
2.4.1 EU Declaration of Conformity and Declaration of Incorporation ......................... 7
2.4.2 Risk Assessment by the Operator.............................................................................. 7
2.4.3 Operations Manager..................................................................................................... 8
2.5 Operating Personnel...................................................................................................................... 9
2.5.1 Obligation of the Operating Personnel...................................................................... 9
2.5.2 Training of the Operating Personnel.......................................................................... 9
2.6 Working Area, Danger Zone, and Safe Area.............................................................................. 9
2.7 Safety Functions..........................................................................................................................10
2.8 Safety Information for Assembly and Commissioning........................................................ 11
2.9 Safety Information on Operation ..............................................................................................11
2.9.1 Emergency Situations ................................................................................................12
2.9.2 Emergency Operation –Moving the Robot without Drive Power ......................12
2.10 Safety Information for Fault Rectification, Cleaning, and Maintenance Work................14
2.11 Residual Danger..........................................................................................................................15
3Transport ...................................................................................................................17
4Description of the Robot System ..........................................................................18
4.1 Scope of Delivery .........................................................................................................................18
4.2 Modules......................................................................................................................................... 19
4.2.1 Robot............................................................................................................................. 19
4.2.2 horstPANEL (operating panel)..................................................................................20
4.2.3 horstCONTROL (switch cabinet)..............................................................................22

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4.3 Protection Devices.......................................................................................................................23
4.3.1 Enabling Switch ...........................................................................................................23
4.3.2 Emergency Stop Button.............................................................................................23
4.4 Add-on Parts & Tools (Option)...................................................................................................23
5Assembly ...................................................................................................................25
5.1 Working Area of the Robot.........................................................................................................25
5.2 Assembly of the Robot ...............................................................................................................26
5.2.1 Mounting Surface........................................................................................................26
5.2.2 Assembling the Robot................................................................................................27
5.2.3 Restricting the Movement Space.............................................................................27
5.3 Assembling Add-on Parts...........................................................................................................28
5.3.1 Pneumatic Connection of Add-on Parts .................................................................29
5.4 Setting Up horstCONTROL.........................................................................................................29
6Electrical Installation................................................................................................30
6.1 Electrical System Warning Notes .............................................................................................30
6.2 Robot Connection........................................................................................................................31
6.3 Power Connection .......................................................................................................................32
6.4 horstCONTROL I/O ......................................................................................................................33
6.4.1 Overview of All Interfaces..........................................................................................34
6.4.2 Safety-critical Inputs/Outputs...................................................................................35
6.4.3 Test Signals A/B..........................................................................................................39
6.4.4 General Digital Inputs .................................................................................................40
6.4.5 General Digital Outputs ..............................................................................................41
6.4.6 +24 V Power Supply....................................................................................................42
6.4.7 Common Features of All Digital Interfaces ............................................................43
6.4.8 Wiring Examples of Safety-critical Inputs/Outputs...............................................45
6.4.9 Wiring Examples of Digital Inputs/Outputs............................................................48
6.5 Tool I/O..........................................................................................................................................49
6.6 Computer Interfaces ...................................................................................................................51
6.6.1 PROFINET (optional)...................................................................................................51
6.6.2 Ethernet.........................................................................................................................51
6.6.3 USB.................................................................................................................................51
7Commissioning.........................................................................................................52
7.1 Switching on the Robot System................................................................................................53
7.2 Initializing the Robot....................................................................................................................54
8Operation ...................................................................................................................57
8.1 Behavior in an Emergency..........................................................................................................57
8.2 Operating Modes .........................................................................................................................58
8.2.1 Teaching mode............................................................................................................59
8.2.2 Automatic Mode..........................................................................................................60

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8.3 Shutdown after End of Operation.............................................................................................61
9Fault Rectification....................................................................................................63
10 Cleaning and Maintenance.....................................................................................64
10.1 Cleaning........................................................................................................................................64
10.2 Maintenance and Repair ...........................................................................................................65
11 Storage.......................................................................................................................66
12 Disassembly and Disposal .....................................................................................67
12.1 Disassembly ................................................................................................................................67
12.2 Disposal........................................................................................................................................67
13 Annex..........................................................................................................................68
13.1 Technical Data ............................................................................................................................68
13.2 Stopping Distances and Stopping Times .............................................................................. 71
13.3 Optional Accessories.................................................................................................................72
13.4 Spare Parts ..................................................................................................................................74
13.5 Type Plates ..................................................................................................................................74
13.6 Overview of Connectors............................................................................................................75
13.7 Terminal Assignment ................................................................................................................76
13.8 Functional Wiring Diagrams of the Electrical Interfaces ....................................................78
13.8.1 horstCONTROL I/O .....................................................................................................78
13.8.2 Tool I/O 79
14 Glossary.....................................................................................................................80

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List of Tables
Table 6-1: Mains connection characteristic values.........................................................................................................32
Table 6-2: Functional difference between emergency stop and safety stop .............................................................35
Table 6-3: Configurable functions for safe inputs ...........................................................................................................38
Table 6-4: Configurable functions for safe outputs.........................................................................................................39
Table 6-5: Test signal characteristic values......................................................................................................................39
Table 6-6: Configurable functions for general digital inputs..........................................................................................40
Table 6-7: Configurable functions for general digital outputs.......................................................................................41
Table 6-8: Characteristic values of the +24 V power supply..........................................................................................42
Table 6-9: Characteristic values of digital I/O horstIO ....................................................................................................43
Table 6-10: Characteristic values of tool inputs/outputs...............................................................................................50
Table 12-1: Materials used...................................................................................................................................................67
Table 13-1: Stopping distances and times with horstFX performance .......................................................................71
Table 13-2: Optional accessories........................................................................................................................................72
Table 13-3: Spare Parts.........................................................................................................................................................74
Table 13-4: Digital I/O horstCONTROL connectors.........................................................................................................75
Table 13-5: Terminal assignment of digital I/O horstCONTROL...................................................................................77

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Abbreviations
µs.......................................................................... Microseconds
AI ........................................................... Assembly Instructions
HI........................................................................ High, Logisch 1
HORST..... Highly Optimized Robotic Systems Technology
I/O .......................................................................... Input/Output
kV ..................................................................................... Kilovolt
kΩ................................................................................... Kiloohm
LO....................................................................... Low, Logisch 0
mA............................................................................ Milliampere
ms ......................................................................... Millisekunden
mΩ................................................................................. Milliohm
OSSD..................................... Output Switching Signal Device
TCP ..................... Tool Center Point (Werkzeugmittelpunkt)
Ω........................................................................................... Ohm

1 Principle
1
1Introduction
1.1 Principle
The Assembly Instructions contain important information on how to operate the robot system in a safe,
proper, and economically efficient way. Adherence to these Assembly Instructions helps to avoid hazards,
reduce repair costs and downtime, and to increase the reliability and service life of the robot system.
The operator is obligated to add instructions arising from existing national or company regulations on
accident prevention and environmental protection to the Assembly Instructions.
The Assembly Instructions must always be available at the site of operation of the robot system.
Read the Assembly Instructions carefully and completely before commissioning the robot sys-
tem.
Treat the Assembly Instructions with care. Illegible or missing Assembly Instructions must be
replaced immediately.
For the efficient and safe control, programming and operation of the robot, please also read the
detailed description of the user software in the Software horstFX user manual, which is always
accessible on www.horstcosmos.com .
1.2 General Information
The Assembly Instructions include a detailed description of the robot system and guidelines for transport
and installation as well as comprehensive instructions for operating the robot system, tips for fault recti-
fication, and information on maintenance.
The robot system delivered may include options that deviate from the text and images shown
in these Assembly Instructions. This is due to the individual adaptation and further develop-
ment of the robot system on the basis of the requests and orders of the individual customers.
These deviations do not constitute a basis for claims of any kind.
The robot system must be used only for the permissible purposes listed in the Assembly Instructions.
The manufacturer assumes no liability for the improper or unauthorized use of the robot system, operat-
ing errors, user errors or improper or insufficient maintenance.
Section 2 Safety of the Assembly Instructions contains instructions and associated information on the
safe use of the robot system. The instructions specified in this section must always be observed.
1.3 Operating Responsibility and Liability
Operating responsibility lies with the operator of the robot system. The operations manager and all oper-
ators are obligated to act according to these Assembly Instructions.
The safety and accident prevention regulations of the following institutions must be observed:
−The country’s laws
−The trade associations
−The responsible commercial liability insurance company.
The operations manager, the operating personnel, or –if the former cannot be held responsible due to a
lack of training or basic knowledge –their supervisory staff will be charged with accidents resulting from
the failure to observe these Assembly Instructions, safety and accident prevention regulations, or a lack
of care.

1 Warranty
2
Therefore, please take due care and caution.
1.3.1 Legal Disclaimer
We expressly stipulate that the manufacturer shall not be liable for damage caused by incorrect or negli-
gent operation or maintenance, or improper use. This also applies to modifications and additions to as
well as conversions of the robot system that may impair its safety. The manufacturer’s liability shall expire
in these cases.
1.4 Warranty
Unless otherwise agreed upon in the purchase contract, we will grant the legally prescribed warranty pe-
riod for the robot system and spare parts, starting on the day of delivery.
The warranty provisions specified in the general terms and conditions of fruitcore robotics GmbH or the
individual purchase contract apply in addition.
1.5 Organizational Measures
The responsibilities when operating the robot system must be clearly defined and observed to ensure that
no unclear responsibilities arise with regard to the aspect of safety (e.g. “Who switches off the robot?”,
“Who secures the robot against unauthorized use?”, “Who controls the safety components?”).
An operations manager must be appointed by the operator. The operations manager is obligated to allow
the operating personnel time for work and safety instruction on the basis of the these Assembly Instruc-
tions. Malfunctions must be reported to the operations manager immediately.
In addition, the operator must observe and provide instruction on generally applicable legal and other
binding regulations on accident prevention and environmental protection.
1.6 Applied Standards and Regulations
The following standards and regulations were applied during the development of the robot system.
−EU Directive 2006/42/EC
Machinery Directive
−DIN EN ISO 10218-1
Robots and robotic devices –Safety requirements –Part 1: Robots
−DIN EN ISO 12100
Safety of Machinery –General principles of design –Risk assessment and risk reduction
−DIN EN ISO 13849-1
Safety of Machinery –Safety-related parts of control systems –
Part 1: General principles of design
−DIN EN ISO 13849-2
Safety of Machinery –Safety-related parts of control systems –Part 2: Validation
−DIN EN ISO 13850
Safety of Machinery –Emergency stop principles of design
−DIN EN ISO 14118
Safety of Machinery –Prevention of unexpected start-up
−DIN EN 60204-1/A1
Safety of Machinery –Electrical equipment of machines –Part 1: General requirements
−DIN EN 60529
Degrees of protection provided by enclosures