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

II
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

V
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

VII
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

1 Signs, symbols
3
−ISO 9409-1
Industrial robots–Mechanical interfaces –Part 1: Plates
1.7 Signs, symbols
The following symbols are used in the Assembly Instructions:
Lists
−Simple lists are marked with “–”.
Instructions for action
All instructions for action for a procedure are listed in chronological order.
Instructions are marked with “”.
Intermediate results and end results of the action are marked with “⇒”.
Note
This symbol stands for information that allows a more effective and economically efficient use of
the robot system.
1.8 Marking of the Safety and Warning Signs
The following safety signs mark all actions that present a danger to life and limb of the operator or others
around the operator.
Make sure to observe these signs and exercise particular caution in these cases. Also pass on the safety
signs to other users.
DANGER!
The sign with the addition DANGER refers to an immediate danger.
The danger will lead to serious injury or death of persons.
The description of the danger is followed by instructions for action that serve to avoid or re-
move the danger.
WARNING!
The sign with the addition WARNING refers to possible danger.
The danger can lead to serious injury or death of a person.
The description of the danger is followed by instructions for action that serve to avoid or re-
move the danger.
CAUTION!
The sign with the addition CAUTION refers to a potentially hazardous situation.
The danger can lead to injury of persons.
The description of the danger is followed by instructions for action that serve to avoid or re-
move the danger.
The safety signs are often used in combination with a pictogram in the text to clarify the source of the
danger.

1 Marking of the Safety and Warning Signs
4
ELECTRICAL VOLTAGE!
This sign is a warning for electricity.
It is posted for all work and operating procedures that are to be observed precisely in order to
prevent danger to persons and the system by electricity.
ATTENTION! Danger of damage to robot or property.
This sign indicates information that, if disregarded, presents a danger to the robot system,
individual modules, or the operating environment. There is no risk of injury.
Wear protective clothing.
Wear your personal protective equipment:
Safety shoes, protective helmet, safety goggles, and work gloves.
Danger of environmental damage.
This sign indicates information that, if disregarded, presents a danger to the environment. There
is no risk of injury.

2 General Safety Information
5
2Safety
2.1 General Safety Information
The HORST robot system is a quality product manufactured in accordance with the recognized rules of
technology. The robot system left the manufacturing plant in perfect condition in terms of safety.
The robot system is designed and built according to the current state of the art in safety technology.
However, there is always a residual risk!
For your own safety, always observe the following:
WARNING!
Incorrect operation or handling of the robot system can lead to severe personal injuries.
 In order to avoid damage, these Assembly Instructions must be read, understood, and
observed.
 Persons who work with the robot system must be familiar with the safety information of
these Assembly Instructions and act according to them.
Always observe the currently valid safety regulations and information.
Make sure to observe the occupational safety regulations specified by the law, the regula-
tory agencies, and the professional associations.
2.2 Proper Use
The HORST robot system is used to implement industrial robot applications and robotics applications in
the area of education. After being programmed by the operator, the robot system is able to execute move-
ments independently. Add-on parts such as grippers or testing instruments can be attached to the robot.
These can be controlled by the robot system.
The robot system must be operated only in dry, level interior spaces on a firm surface. The robot must be
used only within suitable protection devices (e.g. separating protection device, light curtain, or safety laser
scanner).
Note:
−The robot system must be used as intended and only in accordance with the Assembly Instruc-
tions (AI) ) and the enclosed documents. All information and safety instructions of the AI for
the operating personnel must be observed. Any use that differs from or extends beyond this is
considered improper and is expressly prohibited.
−In addition, the operator must observe and provide instruction on generally applicable legal and
other binding regulations on accident prevention and environmental protection.
−All protection devices must be functional in order for the robot system to be used properly.
−Changes to or conversions of the robot system must not be made without the manufacturer’s
approval.
DANGER!
The robot system must not be used in rooms with a potentially explosive atmosphere.

2 Improper Use
6
2.3 Improper Use
Any use that is not described in subsection 2.2 or goes beyond it is considered improper use.
2.3.1 Foreseeable Misuse
The robot system is not intended for hazardous applications. Any use or application that deviates from
the intended use is considered as impermissible misuse.
In the case of foreseeable misuse or improper handling of the robot system, the manufacturer’s
declaration of incorporation expires, as a result of which the operating permit also expires au-
tomatically.
Examples of foreseeable misuse include the following:
−Cutting and welding of workpieces
−Coating/painting
−Use in contact with any kind of liquids (except lubricants intended for the robot system)
−Use in potentially explosive atmospheres
−Use in medical and life-critical applications
−Use prior to the implementation of a risk assessment of the entire application
−Use with applications with insufficient response times of the safety functions
−Use as a climbing aid
−Operation outside of the permissible operating parameters
−Use of the robot system by personnel who have not received the appropriate instruction, train-
ing, or authorization
−Operation of the robot system outside of the specified technical limits
−Use of components that have not been approved by the manufacturer
−Repairs to components performed by unauthorized personnel
−Manipulation of power settings
−Attachment of accessories or add-on parts that are not expressly approved for use by the man-
ufacturer
−Removal or manipulation of protection devices, e.g. covers or speed restrictions
−Use of unsuitable aids, e.g. tools or lifting gear
−Operation of the robot system with defects
−Implementation of maintenance activities without shutting down the robot system according
to the instructions
These forms of misuse by operating personnel or third parties are strictly prohibited:
−The load capacity of the robot must not be exceeded.
−Sensors must not be covered, masked off, or otherwise disabled. The configuration of sensors
must not be changed under any circumstances.
−The enabling switch and other actuating elements must not be bypassed or otherwise manip-
ulated or disabled.
−Work must be performed only in the operating mode which is appropriate for the respective
situation.
−The robot must be used only within suitable protection devices (e.g. separating protection de-
vice, light curtain, or safety laser scanner).

2 Operator’s Duties
7
2.4 Operator’s Duties
2.4.1 EU Declaration of Conformity and Declaration of Incorporation
The robot system is considered partly completed machinery in accordance with the EC Ma-
chinery Directive. The robot system must be commissioned only under the following condi-
tions:
1. All safety functions and protection devices required for final machinery as defined by the
EC Machinery Directive have been added to the robot system.
Or:
2. The robot system is integrated in a system.
Or:
3. The robot system forms a system together with other machinery.
−This system or machinery must correspond to the provisions of the EC Machin-
ery Directive. A CE declaration of conformity must be present. The operator is
solely responsible for ensuring this.
Declaration of Conformity
The operator must prepare a declaration of conformity in accordance with the EC Machinery Directive for
the entire machinery; this constitutes the basis for a corresponding CE marking.
Declaration of Incorporation
The robot system is delivered as partly completed machinery with a declaration of incorporation in ac-
cordance with Annex II B of the Machinery Directive 2006/42/EC.
The declaration of incorporation declares that the commissioning of the partly completed machinery re-
mains impermissible until the partly completed machinery is installed in a piece of machinery or assem-
bled together with other parts into a piece of machinery that corresponds to the provisions of the EC
Machinery Directive, and the EC declaration of conformity in accordance with Annex II A is present.
This includes in particular that corresponding protective measures according to the risk assessment per-
formed by the operator are taken and that these are to be verified and validated. To this end, the robot
system offers a defined scope of safety functions. Emergency stop and safety stop I/Os are prepared in
accordance with EN ISO 10218-1.
The operator must ensure the correct function of external protection devices.
2.4.2 Risk Assessment by the Operator
DANGER!
Add-on parts, workpieces, or combining the robot system with other pieces of machinery can
increase dangers or create new dangers.
In order to ensure safety, robot system HORST must be installed in accordance with the
guidelines specified in the standards DIN EN ISO 12100 and DIN EN ISO 10218-2.
After you have assembled the robot system or integrated it in a system, perform a risk as-
sessment for the entire system.
To prevent dangers, additional protection devices (e.g.separating protection device, light curtain, or safety
laser scanner) must be installed.

2 Operator’s Duties
8
The risks listed below in particular must be observed:
−Crushing, impact, and cutting injuries:
−Between the axes of the robot
−Between the robot and the mounting surface
−Between the linkage of the robot
−Crushing and cutting injuries:
−Between the robot/tool and other objects
−Between the robot/tool and solid surfaces
−Impact injuries caused by the robot
−Crushing and cutting injuries caused by sharp edges:
−Of the robot
−Of the tool
−Of workpieces
−Tilting or falling of the robot.
−During transport
−During assembly
−During operation (due to insufficient attachment)
−Tools/workpieces being flung around or falling down (due to incorrect assembly, design, pro-
gramming, or interruption of the energy supply to the robot or end effector)
−Electrical danger in case of contact between modules and liquids.
−Danger of falling due to lines lying around.
−Danger due to incorrect integration in the control system of an overall system.
−Danger due to incorrect integration in the superordinate emergency stop circuit.
2.4.3 Operations Manager
DANGER!
Possible personal injuries caused by unsafe condition of the system
The operator of the robot system is obligated to designate an operations manager at the
installation location.
The operations manager is obligated to operate the robot system only in perfect and safe
condition.
In addition, the operations manager is obligated:
−to only let persons work on the robot system who are familiar with the fundamental regulations
on occupational safety and accident prevention and who have been trained in handling the
robot system by fruitcore robotics GmbH or by personnel authorized by fruitcore robotics
GmbH.
−to only let persons who have read and understood the AI, and confirmed this with their signa-
ture, to work on the robot system (see Work and Safety Briefing).
−to clearly determine the responsibility of the personnel for operating, converting, repairing, and
maintaining.
−to supervise the safety-conscious behavior of the personnel.
−to encourage the transport and operating personnel to wear protective clothing.
−to provide the personnel with the necessary safety equipment.

2 Operating Personnel
9
The operations manager must conduct checks as to the safety-conscious and danger-conscious
behavior of the operating and maintenance personnel.
2.5 Operating Personnel
2.5.1 Obligation of the Operating Personnel
Before taking up work, all persons commissioned with working on the robot system undertake:
−to observe the fundamental regulations on occupational safety and accident prevention.
−to read the AI and confirm this with their signature.
−to follow the instructions and safety information of the AI.
−to check the robot system in terms of safety and proper function before starting work.
−to contact the operations manager or fruitcore robotics GmbH in case of questions.
2.5.2 Training of the Operating Personnel
DANGER!
Possible personal injuries caused by untrained operating personnel
The operating personnel must be trained on the work with and dangers of the robot system
by fruitcore robotics GmbH or authorized personnel commissioned by fruitcore robotics
GmbH.
Persons who have not received this training are not permitted to operate the robot system.
DANGER!
Possible personal injuries caused by the operation of persons undergoing training
Persons to be trained or taught as well as apprentices are only permitted to operate the ro-
bot system if supervision by a trained person with technical or electrotechnical training
(teaching personnel) is ensured.
The operating personnel must be trained on the work with and dangers of the robot system by fruitcore
robotics GmbH or authorized personnel commissioned by fruitcore robotics GmbH.
The operating personnel must be at least 18 years old and both physically and mentally fit to operate the
robot system.
Instructed personnel with technical training may be used for the following activities:
−Operating the robot system in automatic mode
−Adjusting the system parameters (teaching modes T1 and T2)
Instructed personnel with technical and electrotechnical training may also be used for the following ac-
tivities:
−Assembly and commissioning of the robot system
−Troubleshooting and fault rectification
−Inspection, maintenance, and repair
2.6 Working Area, Danger Zone, and Safe Area
The working area is a defined 3D space within the range of the robot. When tools, measuring devices, and
workpieces are attached, the range of the robot and therefore its working area change.
The stopping distance is calculated on the basis of the reaction distance and braking distance of the
robot.

2 Safety Functions
10
The danger zone includes the working area and stopping distance of the robot. Persons must not be in
the danger zone while the robot is in operation.
DANGER!
Due to the robot’s automatic movement, sudden dangers must be expected within the danger
zone. Moving modules may cause personal injury or property damage.
The robot system must be operated only in technically perfect condition and with active
safety equipment.
The robot must be used only within suitable protection devices (e.g. separating protection
device, light curtain, or safety laser scanner). The protection devices must stop the robot’s
movement within the danger zone.
The safe area is located outside the danger zone. Persons may be in this area during all operating modes.
2.7 Safety Functions
The robot control is equipped with two different types of safety functions, both of which bring the robot
into a safe condition. A safe state is achieved by braking all of the robot’s drive axles.
The two fundamental emergency stop and safety stop safety functions are described below.
Emergency Stop
Bringing about a safe condition of the robot in the event of an emergency situation. This safety function
is available in all operating modes. It takes precedence over all safety functions. It is triggered by the
emergency stop button or external safety controls. External emergency stop devices are connected to the
emergency stop inputs of the switch cabinet, hereinafter referred to as the horstCONTROL.
This safety function must be used in emergency situations exclusively in order to bring the robot into a
safe condition. The emergency stop must not be used for process-related stops.
Safety Stop
Bringing about a safe condition of the robot for process-related and safety-critical situations. This safety
function is to be used for process-related stops during which operating personnel must be able to inter-
vene in the danger zone.
The purpose of both types of safety functions is to bring about a safe condition of the robot.
The safe condition is marked by the following properties:
−Emergency stop: A category 1 stop is triggered. The robot is braked actively until it comes to a
standstill; the brakes are applied, and the energy of the drives is then switched off.
−Safety stop: A category 2 stop is triggered. The robot is actively braked until it comes to a
standstill. The drive power is not switched off. The safe standstill is monitored.
The robot control has other safety functions. These are described in the subsections on the configurable
safety functions from page 37.
The safety-related performance of the control system corresponds to PL “d” with structure
category 3 according to DIN EN ISO 13849-1:2006. It is defined by the risk assessment of the
robot system or DIN EN ISO 10218-1.

2 Safety Information for Assembly and Commissioning
11
2.8 Safety Information for Assembly and Commissioning
ELECTRICAL VOLTAGE!
Possible personal injuries caused by applied electricity
Work on the electrical equipment must be performed only by specialist personnel with ap-
propriate training and in accordance with the electrotechnical rules.
Make sure that the power supply is switched off while working on the robot and that it can-
not be switched on again by accident.
Use only the included cables to connect to the power grid. Do not use damaged cables.
DANGER!
Danger resulting from incorrect assembly and commissioning
Assembly and commissioning must be performed only by persons with technical and elec-
trotechnical training who were also authorized by fruitcore robotics GmbH.
DANGER!
Danger due to missing protection devices and safety equipment as well as defective/damaged
modules or accessories.
Only commission the robot system with functional protection devices and safety equipment
as well as functional modules or accessories.
WARNING!
Danger of impact and crushing due to robot movement
Close off the installation area, and protect it against access by unauthorized persons.
Secure the horstPANEL (operating panel) and horstCONTROL (switch cabinet) against oper-
ation by unauthorized persons.
CAUTION!
Risk of injury due to overloading or the robot falling
The robot must be lifted by at least two persons in order to prevent overloading or the robot
from falling.
CAUTION!
Damage due to the formation of condensate
Never switch the robot on immediately if it has been brought from a cold environment into a
warm environment. The condensate that forms in these conditions could damage the electron-
ics. We recommend leaving the system overnight to adjust to the ambient temperature.
2.9 Safety Information on Operation
DANGER!
Possible personal injuries caused by careless handling of the system.
Refrain from any unsafe method of working!
Make sure that the robot arm and the tool are screwed on properly and safely.
Ensure that there is sufficient room for the robot arm to move freely. There must be no obsta-
cles in the working area.
The mounting surface of the robot must be stationary within a firmly installed protection de-
vice.
Note that the range of the robot and thus the danger zone change with add-on parts and
workpieces.

2 Safety Information on Operation
12
If the robot is combined with other machinery in a system, make sure that the other machin-
ery cannot damage the robot.
Do not expose the robot system to permanent magnetic fields. Very strong magnetic fields
can damage the robot system.
Ensure that suitable protection devices (e.g. separating protection device, light curtain, or
safety laser scanner) were installed. The protection devices must stop the robot’s movement
within the danger zone. Check the protection devices for proper function every day.
Do not enter the danger zone of the robot during operation, and do not touch the robot.
Only operate the robot system in undamaged condition. Never modify the robot system.
fruitcore robotics GmbH excludes any liability if the product has been modified.
Check the emergency stop and safety stop functions daily.
The robot system must be checked for externally visible damage and defects at least once
per day/shift. Changes or damage that have occurred must be reported to the person or of-
fice responsible immediately.
In the event of malfunctions, switch off the robot system immediately and secure it
against restarting, including by third parties. Report malfunctions immediately to the op-
erations manager and rectify or have them rectified immediately.
Only perform switch on and switch off processes in accordance with the Assembly instruc-
tions.
It is only permissible to disconnect the horstPANEL from or connect it to the horstCONTROL
when it is disconnected from the power supply.
Ensure that only the connected horstPANEL is in the vicinity of the robot to avoid confusions
with inactive emergency stop buttons.
2.9.1 Emergency Situations
DANGER!
Due to the robot system’s automatic movement, sudden dangers must be expected within the
danger zone. Moving modules may cause personal injury or property damage.
The robot system must be operated only in technically perfect condition and with functional
protection devices.
The robot must be used only within suitable protection devices (e.g. separating protection
device, light curtain, or safety laser scanner).
In the event of an emergency, the robot system must be stopped with the emergency stop button Emer-
gency Stop Button, page 23.
When integrated in a complete system, the robot system must be integrated in the emergency
stop circuit of the higher-level system. Observe the information on this in subsection Safety-
critical Inputs/Outputs , page35.
2.9.2 Emergency Operation –Moving the Robot without Drive Power
The axes of the robot must be moved without drive power only in emergencies, in particular for the pur-
pose of freeing persons. The personnel performing the rescue operation must have undergone basic
technical training and observe the following warnings and instructions. Specialist personnel from fruitcore
robotics GmbH must be called for recommissioning the system.