Hanwha HCR-12 User manual

HCR-12
Collaborative Robot
User Manual
Aug. 2019
V 2.001

3
Preface
Before installing the product, please read this manual fully and make sure you follow
the instructions in it.
The content of the manual is maintained latest as of the date when it is written. The
product information is subject to change without prior notice to users.
If you are uncertain about any requirements, recommendations or safety procedures
described in the manual, please, consult with Hanwha Precision Machinery Co.
Users are responsible for any damages caused by their misuse neglecting these
instructions below.
Note Some of illustrations in the manual intends to help users in
understanding the system concepts and installation issues. The actual
product may differ from the manual.
Please keep this manual in a safe place for future reference.
Voltage: 100~240VAC, 50/60Hz (1kW) (It should be connected to the
neutral cable which is connected with grounding line with one phase of
the 3 phase cables.)
Status of load installation: Load is not exceeding the payload of Robot.
Please check the grounding line connection in plant and operating cell.
(It can be refer to section 3.3 to check the location of grounding line.)
- Any plants and cells with the inappropriate grounding line may have
the negative influence such as noise on the communication line between
robot and system.
- Especially, if robot is installed with the equipment requiring large
current such as heater, motor, separate additional grounding line is
required.

4
Copyrights
The copyrights and intellectual property rights of all the content and diagrams in the
manual belong to Hanwha Precision Machinery Co.
Thus, illegal use, duplication, distribution or dissemination of the manual without prior
written approval by Hanwha Precision Machinery Co. is strictly prohibited and such an
activity is an infringement of the intellectual property rights of Hanwha Precision
Machinery Co.
Users are responsible for any damages caused by their misuse or modification of the
patent rights for the equipment.
The information provided by the manual is deemed trustworthy by Hanwha Precision
Machinery Co. Hanwha Precision Machinery Co. is not responsible for any situations
arising due to inaccuracy or typo in the content of the manual.
The information provided in the manual is subject to change without prior notice and
for more details about revisions made in the manual, please visit the homepage of
Hanwha Precision Machinery Co. (http://www.hanwharobotics.com)
©2019 Hanwha Precision Machinery Co., Ltd. All rights reserved

Table of Contents
5
Table of Contents
PREFACE ................................................................................................................................................................... 3
COPYRIGHTS ............................................................................................................................................................. 4
CHAPTER 1 PRODUCT OVERVIEW .................................................................................................................... 13
1.1 COLLABORATIVE ROBOT SYSTEM......................................................................................................13
1.2 SYSTEM COMPONENTS .....................................................................................................................15
1.3 BASIC SYSTEM CONFIGURATION .......................................................................................................16
1.4 OVERVIEW OF ROBOT ARMS.............................................................................................................17
1.5 OVERVIEW OF ROBOT CONTROLLER ................................................................................................19
Front.............................................................................................................................................19
Bottom..........................................................................................................................................20
1.6 OVERVIEW OF TEACHING PENDANT..................................................................................................21
Front.............................................................................................................................................21
Rear ..............................................................................................................................................22
1.7 AXIAL COORDINATES AND OPERATIONAL RANGE ............................................................................23
1.8 ROBOT'S WORKING RANGE ..............................................................................................................25
1.9 MAXIMUM LOAD CAPACITY FOR THE TOOL.......................................................................................26
CHAPTER 2 SAFETY .......................................................................................................................................... 27
2.1 SAFETY MARKS IN THE USER MANUAL..............................................................................................27
2.2 GENERAL SAFETY CAUTIONS ............................................................................................................28
2.3 INTENDED USE..................................................................................................................................29
2.4 POTENTIAL DANGERS .......................................................................................................................30
2.5 LIMITATION OF LIABILITY .................................................................................................................30
2.6 TRANSPORTATION ............................................................................................................................31
2.7 EMERGENCY STOP ............................................................................................................................32
Using emergency stop ...................................................................................................................32
Canceling emergency stop ............................................................................................................32
2.8 SAFETY FENCE ..................................................................................................................................33
2.9 LIMITS OF SPEED AND ROTATIONAL ANGLES ....................................................................................33
2.10 OPERATING ROBOTS WITHOUT DRIVING POWER ..............................................................................33
2.11 SAFETY CONTROLLER.......................................................................................................................33
2.12 RISK ASSESSMENT .............................................................................................................................33
CHAPTER 3 INSTALLATION ............................................................................................................................... 35

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3.1 INSTALLATION LOCATIONS ...............................................................................................................35
3.2 INSTALLATION TYPES........................................................................................................................36
3.3 FIXING ROBOTS ................................................................................................................................38
3.4 CONNECTING TOOLS TO ROBOTS.....................................................................................................39
3.5 CONNECTING CABLES.......................................................................................................................40
Connecting the robot arm to the robot controller........................................................................40
Connecting the power supply to the robot controller...................................................................41
3.6 FIXING THE CONTROLLER BOX ........................................................................................................42
3.7 OVERVIEW OF CONTROLLER I/O......................................................................................................43
3.8 COMMON SPEC FOR DIGITAL I/O .....................................................................................................43
3.9 CONFIGURING THE SAFETY INPUT .....................................................................................................46
Initial safety configuration ............................................................................................................47
Connecting the emergency stop button ........................................................................................48
Safety protection stop and restart.................................................................................................48
3.10 CONFIGURING THE GENERAL DIGITAL I/O .......................................................................................49
Load control with digital outputs.................................................................................................49
Digital input control using buttons...............................................................................................50
Communicating with other equipment or PLC ............................................................................50
3.11 CONFIGURING THE GENERAL ANALOG I/O ......................................................................................51
Analog output...............................................................................................................................52
Analog input.................................................................................................................................52
CHAPTER 4 GETTING STARTED ......................................................................................................................... 53
4.1 TURNING ON THE ROBOT CONTROLLER...........................................................................................53
4.2 TURNING ON THE TEACHING PENDANT............................................................................................54
CHAPTER 5 SOFTWARE OVERVIEW .................................................................................................................. 55
5.1 MENU OVERVIEW.............................................................................................................................55
Expanding menu...........................................................................................................................55
Robot Operation ..........................................................................................................................55
Programming ................................................................................................................................55
Monitoring ...................................................................................................................................56
Robot Setting................................................................................................................................56
Safety Setting ................................................................................................................................56
Device Setting ...............................................................................................................................56
Management.................................................................................................................................56
SW Configuration.........................................................................................................................56
Message ........................................................................................................................................56

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Manual Move...............................................................................................................................56
5.2 3D PREVIEW SCREEN ........................................................................................................................57
Screen display setting button ........................................................................................................57
Robot task control button............................................................................................................58
5.3 MANUAL MOVE SCREEN ..................................................................................................................59
5.4 VIRTUAL KEYPAD..............................................................................................................................61
Text keypad..................................................................................................................................61
Number keypad............................................................................................................................62
Expression keypad........................................................................................................................62
CHAPTER 6 REGISTERING ROBOTS AND USERS ................................................................................................ 64
6.1 MANAGING ROBOTS.........................................................................................................................64
Registering robots.........................................................................................................................65
Deleting robots .............................................................................................................................65
Modifying the robot name............................................................................................................66
6.2 MANAGING USERS............................................................................................................................67
Adding users and setting authorities.............................................................................................67
Menu available to each authority.................................................................................................68
6.3 LOGIN/LOGOUT ...............................................................................................................................69
Logging in.....................................................................................................................................69
Logging out ..................................................................................................................................70
6.4 CHECKING STATUS............................................................................................................................70
Checking the robot status.............................................................................................................70
Checking errors ............................................................................................................................70
Checking the software version......................................................................................................71
CHAPTER 7 SETTING ROBOTS ........................................................................................................................... 72
7.1 SETTING THE ROBOT INSTALLATION ANGLES....................................................................................72
7.2 SETTING TCP ...................................................................................................................................73
Creating a new TCP profile ..........................................................................................................74
Calculating the TCP position........................................................................................................76
Setting the TCP orientation ..........................................................................................................79
Changing the TCP profile name ...................................................................................................81
Editing the TCP profile.................................................................................................................81
Deleting the TCP profile ...............................................................................................................82
7.3 SETTING INPUTS/OUTPUTS................................................................................................................83
Types of digital I/O ......................................................................................................................83
Editing the digital inputs/outputs settings ....................................................................................84

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Editing the digital outputs settings................................................................................................84
Types of analog I/O .....................................................................................................................85
Editing the analog I/O setting.......................................................................................................86
7.4 COORDINATES..................................................................................................................................87
Registering points .........................................................................................................................87
Registering line coordinates ..........................................................................................................88
Registering plane coordinates .......................................................................................................88
7.5 SETTING GLOBAL VARIABLES ............................................................................................................89
7.6 I/O BIT OPERATION .........................................................................................................................90
Add/Delete ...................................................................................................................................90
I/O bit operation settings .............................................................................................................90
CHAPTER 8 SAFETY SETTINGS........................................................................................................................... 91
8.1 LIMITING ROBOT MOVEMENT..........................................................................................................91
Default settings .............................................................................................................................92
Manual setting method.................................................................................................................92
8.2 SETTING SAFETY BOUNDARIES ..........................................................................................................94
Adding safety boundary planes.....................................................................................................94
Viewing safety boundary planes ...................................................................................................95
Applying safety boundaries...........................................................................................................96
Changing the name of safety boundaries......................................................................................97
Deleting safety boundary settings .................................................................................................97
8.3 SETTING TOOL BOUNDARIES.............................................................................................................99
Adding Tool Safety Boundary Surfaces ........................................................................................99
Setting Tool Safety Boundary Surfaces .......................................................................................100
Applying Tool Safety Boundary Surfaces ...................................................................................101
8.4 SETTING REDUNDANT I/O..............................................................................................................101
8.5 SETTING SAFEGUARD I/O................................................................................................................103
8.6 EXCEEDING SAFETY LIMIT OF JOINTS..............................................................................................104
CHAPTER 9 PROGRAMMING ...........................................................................................................................105
9.1 HOW TO USE COMMANDS ..............................................................................................................105
Selecting a flowchart...................................................................................................................105
Type of commands .....................................................................................................................106
Additional Commands................................................................................................................107
Entering commands....................................................................................................................108
Check Icon Status.......................................................................................................................108
Changing command names ........................................................................................................108

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Deleting commands ....................................................................................................................109
Searching Commands .................................................................................................................109
Skipping Commands...................................................................................................................109
Tree ............................................................................................................................................110
9.2 SETTING VARIABLES........................................................................................................................111
Adding variables .........................................................................................................................111
Modifying variables....................................................................................................................112
Deleting variables .......................................................................................................................112
Variable Monitoring...................................................................................................................112
9.3 EDITING PROGRAMS........................................................................................................................113
Overview of edit menu ...............................................................................................................113
Example of program editing .......................................................................................................114
Undo Function............................................................................................................................115
9.4 MANAGING A PROGRAM ................................................................................................................116
Saving a program........................................................................................................................116
Making a new program..............................................................................................................116
Loading a program.....................................................................................................................117
Deleting a program.....................................................................................................................117
Export as script ..........................................................................................................................118
Export Program File ...................................................................................................................118
9.5 USING TEMPLATES ..........................................................................................................................119
Saving as a template ...................................................................................................................119
Loading a template .....................................................................................................................120
Deleting a template .....................................................................................................................120
9.6 APPLYING PROGRAMS .....................................................................................................................121
9.7 MOVE COMMAND ..........................................................................................................................122
Selecting a movement method ....................................................................................................122
Radius of Linear .........................................................................................................................124
Don’t stop at this point ..............................................................................................................124
Blending......................................................................................................................................124
Advanced....................................................................................................................................126
Setting the coordinates for movement ........................................................................................126
Displaying as groups...................................................................................................................127
9.8 IF COMMAND.................................................................................................................................128
9.9 LOOP COMMAND .........................................................................................................................129
9.10 SWITCH COMMAND .....................................................................................................................130
9.11 WAIT COMMAND..........................................................................................................................131

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9.12 SET COMMAND .............................................................................................................................132
9.13 FOLDER ..........................................................................................................................................133
Change Programed Icons into Folder .........................................................................................133
Create New Folder .....................................................................................................................133
9.14 MESSAGE........................................................................................................................................134
Output format ............................................................................................................................134
Message operation......................................................................................................................134
Message format ..........................................................................................................................135
Select message.............................................................................................................................135
9.15 PATTERN COMMAND ..................................................................................................................136
Pattern types ...............................................................................................................................136
Setting the pattern coordinates ...................................................................................................137
Setting repeat counts...................................................................................................................138
Advanced commands for patterns ..............................................................................................138
Setting pattern points..................................................................................................................139
9.16 USING A SUB PROGRAM ..................................................................................................................140
Making a sub program...............................................................................................................140
Saving and loading a sub program .............................................................................................141
Entering a sub program ..............................................................................................................141
9.17 CONVEYOR ....................................................................................................................................143
Conveyor Setting ........................................................................................................................143
Conveyor Start Options..............................................................................................................144
Setting Conveyor Command.......................................................................................................144
9.18 VISION COMMAND.......................................................................................................................145
Setting basic options ...................................................................................................................145
Setting the movement speed........................................................................................................145
Setting the movement location....................................................................................................146
9.19 THREAD .........................................................................................................................................147
Thread Tab.................................................................................................................................147
Thread Creation .........................................................................................................................148
Event Tab ...................................................................................................................................148
9.20 SCRIPT ............................................................................................................................................149
Script Viewer ..............................................................................................................................149
9.21 PATH COMMAND ...........................................................................................................................150
Recording Paths..........................................................................................................................150
CHAPTER 10 STARTING THE ROBOT ..................................................................................................................152
Turning ON/OFF the robot .......................................................................................................153

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Monitoring .................................................................................................................................153
Checking and setting the robot operation data ..........................................................................154
Operating the robot....................................................................................................................155
Locking Screen ...........................................................................................................................156
CHAPTER 11 MONITORING ...............................................................................................................................157
11.1 MONITORING THE ROBOT..............................................................................................................157
Monitoring the robot positions ..................................................................................................157
Checking the robot status...........................................................................................................158
11.2 MONITORING INPUTS/OUTPUTS .....................................................................................................158
Monitoring controller inputs/outputs.........................................................................................159
Monitoring tool inputs/outputs..................................................................................................160
11.3 UNILIZATION..................................................................................................................................161
CHAPTER 12 DEVICE SETTING ...........................................................................................................................162
12.1 CONFIGURING MODBUS TCP .......................................................................................................162
Registering Devices .....................................................................................................................163
Editing/copying the device settings.............................................................................................164
Registering I/O ...........................................................................................................................165
Viewing the communication status.............................................................................................166
Viewing and setting the I/O values.............................................................................................167
Editing I/O settings.....................................................................................................................168
Deleting I/O................................................................................................................................168
12.2 USING A VISION SYSTEM .................................................................................................................169
12.3 ADDING AND SETTING VISION EQUIPMENT ......................................................................................170
Adding a vision equipment .........................................................................................................170
Setting a vision equipment..........................................................................................................170
12.4 SETTING VISION WORKSPACE .........................................................................................................172
Adding Vision Workspace..........................................................................................................172
Understanding rotation offsets....................................................................................................173
CHAPTER 13 ENVIRONMENT SETTING ..............................................................................................................175
13.1 GENERAL SETTING..........................................................................................................................175
13.2 NETWORK SETTING ........................................................................................................................176
CHAPTER 14 TURNING OFF THE SYSTEM...........................................................................................................177
14.1 SHUTTING DOWN THE OPERATION SOFTWARE ...............................................................................177
14.2 TURNING OFF CONTROLLERS.........................................................................................................177
CHAPTER 15 MAINTENANCE .............................................................................................................................178

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15.1 INSPECTION ITEMS AND PERIODS ....................................................................................................178
15.2 CHECKING THE ROBOT ARM ..........................................................................................................179
Inspection period ........................................................................................................................179
Checking and cleaning the robot arm.........................................................................................179
15.3 CHECKING THE CONTROLLER ........................................................................................................179
Inspection period ........................................................................................................................179
Checking and cleaning the controller .........................................................................................179
Cleaning and replacing the filter.................................................................................................180
15.4 VIEWING AND MANAGING LOGS ....................................................................................................181
Deleting Logs..............................................................................................................................181
Exporting Logs ...........................................................................................................................181
15.5 MANAGING THE ROBOT SYSTEM CONFIGURATION.........................................................................182
Packaging posture.......................................................................................................................182
Factory reset ...............................................................................................................................183
Use Default Program ..................................................................................................................183
Exporting the configurations ......................................................................................................183
Importing the configurations ......................................................................................................184
15.6 SOFTWARE UPDATE.........................................................................................................................186
Cautions during update ..............................................................................................................186
Updating the operation software ................................................................................................186
APPENDIX A WARRANTY ..............................................................................................................................188
Warranty ....................................................................................................................................188
Warranty period .........................................................................................................................188
Limitation of Liability.................................................................................................................188
APPENDIX B CERTIFICATION .........................................................................................................................189
Safety ..........................................................................................................................................189
MD(Machinery Directive) ..........................................................................................................190
EMC (Electro Magnetic Compatibility) .....................................................................................191
APPENDIX C DIMENSIONS FOR INSTALLATION .............................................................................................192
APPENDIX D TOOL FLANGE CROSS SECTION .................................................................................................193
APPENDIX E PORT PIN MAP .........................................................................................................................194
APPENDIX F SYSTEM SPECIFICATIONS ..........................................................................................................195
APPENDIX G STOPPING TIME AND DISTANCE ...............................................................................................197
APPENDIX H ERROR CODES...........................................................................................................................199

Chapter 1 Product Overview
13
Chapter 1 Product Overview
1.1 Collaborative Robot System
Hanwha Precision Machinery's collaborative robot, HCR-12 is a user-friendly robot
that provides an automation environment where it can safely collaborate next to
humans in various fields.
Easysetting
By using the direct teaching feature and the intuitive S/W GUI, users can easily
configure and control the robot.
While holding the robot gently, users can implement desired movements, so that the robot
can detect and memorize movements.
Users can preview the robot movement in a real time 3D and use the icon based intuitive
GUI for easy operation.
As the installation method is simple, even if users are not robot engineers, they can easily
configure the initial setting and program the robot.
Flexiblerearrangement
Users can easily rearrange the robot, so that it can be applied to various processes easily
and quickly.
Since users can operate the robot in small space, it is possible to rearrange the robot
without changing the layout of the manufacturing line.
The robot is light weighted and easy to move, and its simple programming environment
allows the robot to be easily adapted to high-mix, low-volume production.

Chapter 1 Product Overview
14
Safecollaboration
Using the various safety features, users can safely work next to the robot without using
additional safety tools or devices.
The robot is automatically stopped when it detects an impact, so as long as the working
range of the robot and the user are guaranteed, it can be installed anywhere for safe use.
Caution
For HCR-12 model, the serial number of controller and robot body must match. If it
does not match, the following error message appears,
Please check with the manager or Hanwha Precision Machinery C / S.
[CODE 2043001]
Calibration data of controller and robot body do
not match. Please check with your administrator to
see if the data match. The system will shut down.

Chapter 1 Product Overview
15
1.2 System Components
The following is a list of system components.
Robot arm Teaching pendant
Robot controller Teaching pendant fixing bracket
12 pin tool cable User manual

Chapter 1 Product Overview
16
The following list indicates the quantity of each component.
Robot Robot arm 1 EA
Controller and teaching
pendant
Robot controller 1 EA
Teaching pendant 1 EA
Teaching pendant fixing bracket 1 EA
Controller power cable 1 EA
Robot communication cable 1 EA
Robot power cable 1 EA
Others
12 pin tool cable 1 EA
User manual 1 EA
1.3 Basic System Configuration
Robot arm: It is an industrial collaborative robot that can be used to convey objects or
assemble parts, and it can be used by attaching various tools such as grippers.
Robot controller: Can control the robot arm's various movements according to the
program prepared by the user. It can be connected with various devices and equipment
through its various I/O ports.
Teaching Pendant (TP): It is a device used for system operation. It can teach the robot a
specific position or control and configure the robot in many ways.
Robot arm
Robot controller
Teaching
pendant
Power
supply &
network
Command &
monitoring

Chapter 1 Product Overview
17
1.4 Overview of Robot Arms
Partsandjoints
➊ Tool Flange ➎
Upper Arm
➋J5_J6 ➏J2
➌
Lower Arm ➐ J1
➍
J3_J4

Chapter 1 Product Overview
18
Functions
No. Name Description
Tool flange
It is the area in the robot where a tool is mounted.
For more details, refer to 3.4 Connecting Tools to
Robots.
Tool I/O
It is the I/O port used to control a tool.
For more details about specifications, refer to
Appendix E Port Pin Map.
EtherCAT
It is the Ethernet based port used for communication
with a tool. For more details about specifications, refer
to
Appendix
EAppendix E Port Pin Map.
LED
Indicates the status of robot.
Green: Operation mode
Blue: Direct teaching mode
Red: Emergency stop mode
Pink: Exceeding joint range limits in direct teaching
Robot base It is the area in the robot that is fixed to the ground or
wall.

Chapter 1 Product Overview
19
1.5 Overview of Robot Controller
Front
No. Name
Handle
Air exhaust hole (exhaust hole filter)
Air intake hole (intake hole filter)
Controller cover locking screw

Teaching pendant fixing hook

Controller fixing bracket

Teaching pendant fixing bracket

Chapter 1 Product Overview
20
Bottom
No. Name
Robot communication connector
Robot power connector
Power button
AC power socket