Hanwha HCR-3 User manual

HCR-3
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
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Table of Contents
PREFACE .................................................................................................................................................... 3
COPYRIGHTS .................................................................................................................................................... 4
CHAPTER 1 PRODUCT OVERVIEW ................................................................................................................ 13
1.1 COLLABORATIVE ROBOT SYSTEM......................................................................................................13
1.2SYSTEM 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 ....................................................................................34
2.10 OPERATING ROBOTS WITHOUT DRIVING POWER ..............................................................................34
2.11 SAFETY CONTROLLER.......................................................................................................................34
2.12 RISK ASSESSMENT .............................................................................................................................34
CHAPTER 3 INSTALLATION ........................................................................................................................... 36
3.1 INSTALLATION LOCATIONS ...............................................................................................................36
3.2 INSTALLATION TYPES........................................................................................................................37

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3.3 FIXING ROBOTS ................................................................................................................................39
3.4 CONNECTING TOOLS TO ROBOTS.....................................................................................................40
3.5 CONNECTING CABLES.......................................................................................................................41
Connecting the teaching pendant to the robot controller .............................................................41
Connecting the robot arm to the robot controller........................................................................41
Connecting the power supply to the robot controller...................................................................42
3.6 FIXING THE CONTROLLER BOX ........................................................................................................43
3.7 OVERVIEW OF CONTROLLER I/O......................................................................................................44
3.8 COMMON SPEC FOR DIGITAL I/O .....................................................................................................44
3.9 CONFIGURING THE SAFETY INPUT .....................................................................................................47
Initial safety configuration ............................................................................................................48
Connecting the emergency stop button ........................................................................................49
Safety protection stop and restart.................................................................................................49
3.10 CONFIGURING THE GENERAL DIGITAL I/O .......................................................................................50
Load control with digital outputs.................................................................................................50
Digital input control using buttons...............................................................................................51
Communicating with other equipment or PLC ............................................................................51
3.11 CONFIGURING THE GENERAL ANALOG I/O ......................................................................................52
Analog output...............................................................................................................................53
Analog input.................................................................................................................................53
CHAPTER 4 GETTING STARTED ..................................................................................................................... 54
4.1 TURNING ON THE ROBOT CONTROLLER...........................................................................................54
4.2 TURNING ON THE TEACHING PENDANT............................................................................................55
CHAPTER 5 SOFTWARE OVERVIEW .............................................................................................................. 56
5.1 MENU OVERVIEW.............................................................................................................................56
Expanding menu...........................................................................................................................56
Robot Operation ..........................................................................................................................56
Programming ................................................................................................................................56
Monitoring ...................................................................................................................................57
Robot Setting................................................................................................................................57
Safety Setting ................................................................................................................................57
Device Setting ...............................................................................................................................57
Management.................................................................................................................................57
SW Configuration.........................................................................................................................57
Message ........................................................................................................................................57
Manual Move...............................................................................................................................57
5.2 3D PREVIEW SCREEN ........................................................................................................................58

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Screen display setting button ........................................................................................................58
Robot task control button............................................................................................................59
5.3 MANUAL MOVE SCREEN ..................................................................................................................60
5.4 VIRTUAL KEYPAD..............................................................................................................................62
Text keypad..................................................................................................................................62
Number keypad............................................................................................................................63
Expression keypad........................................................................................................................63
CHAPTER 6 REGISTERING ROBOTS AND USERS ............................................................................................ 65
6.1 MANAGING ROBOTS.........................................................................................................................65
Registering robots.........................................................................................................................66
Deleting robots .............................................................................................................................66
Modifying the robot name............................................................................................................67
6.2 MANAGING USERS............................................................................................................................68
Adding users and setting authorities .............................................................................................68
Menu available to each authority .................................................................................................69
6.3 LOGIN/LOGOUT ...............................................................................................................................70
Logging in.....................................................................................................................................70
Logging out ..................................................................................................................................71
6.4 CHECKING STATUS............................................................................................................................71
Checking robot status...................................................................................................................71
Checking errors............................................................................................................................71
Checking the software version....................................................................................................72
CHAPTER 7 SETTING ROBOTS....................................................................................................................... 73
7.1 SETTING THE ROBOT INSTALLATION ANGLES....................................................................................73
7.2 SETTING TCP ...................................................................................................................................74
Creating a new TCP profile ..........................................................................................................75
Calculating the TCP position........................................................................................................77
Setting the TCP orientation ..........................................................................................................80
Changing the TCP profile name ...................................................................................................82
Editing the TCP profile.................................................................................................................82
Deleting the TCP profile ...............................................................................................................83
7.3 SETTING INPUTS/OUTPUTS................................................................................................................84
Types of digital I/O ......................................................................................................................84
Editing the digital inputs settings..................................................................................................85
Editing the digital outputs settings................................................................................................85
Types of analog I/O .....................................................................................................................86
Editing the analog I/O setting.......................................................................................................87

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7.4COORDINATES..................................................................................................................................88
Registering points .........................................................................................................................88
Registering line coordinates ..........................................................................................................89
Registering plane coordinates .......................................................................................................89
7.5 SETTING GLOBAL VARIABLES ............................................................................................................90
7.6 I/O BIT OPERATION .........................................................................................................................91
Add/Delete ...................................................................................................................................91
I/O bit operation settings .............................................................................................................91
CHAPTER 8 SAFETY SETTINGS ...................................................................................................................... 92
8.1 LIMITING ROBOT MOVEMENT..........................................................................................................92
Default settings .............................................................................................................................93
Manual setting method.................................................................................................................93
8.2 SETTING SAFETY BOUNDARIES ..........................................................................................................95
Adding safety boundary planes.....................................................................................................95
Viewing safety boundary planes ...................................................................................................96
Applying safety boundaries...........................................................................................................97
Changing the name of safety boundaries......................................................................................98
Deleting safety boundary settings .................................................................................................98
8.3 SETTING TOOL BOUNDARIES...........................................................................................................100
Adding Tool Safety Boundary Surfaces ......................................................................................100
Setting Tool Safety Boundary Surfaces .......................................................................................101
Applying Tool Safety Boundary Surfaces ...................................................................................101
8.4 SETTING REDUNDANT I/O..............................................................................................................102
8.5 SETTING SAFEGUARD I/O................................................................................................................104
8.6 EXCEEDING SAFETY LIMIT OF JOINTS..............................................................................................105
CHAPTER 9 PROGRAMMING.......................................................................................................................106
9.1 HOW TO USE COMMANDS ..............................................................................................................106
Selecting a flowchart...................................................................................................................106
Type of commands .....................................................................................................................107
Additional Commands................................................................................................................108
Entering commands....................................................................................................................109
Check Icon Status.......................................................................................................................109
Changing command names ........................................................................................................109
Deleting commands ....................................................................................................................110
Searching Commands .................................................................................................................110
Skipping Commands...................................................................................................................110
Tree ............................................................................................................................................111
9.2 SETTING VARIABLES........................................................................................................................112

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Adding variables .........................................................................................................................112
Modifying variables....................................................................................................................113
Deleting variables .......................................................................................................................113
Variable Monitoring...................................................................................................................113
9.3 EDITING PROGRAMS........................................................................................................................114
Overview of edit menu ...............................................................................................................114
Example of program editing .......................................................................................................115
Undo Function............................................................................................................................116
9.4 MANAGING A PROGRAM ................................................................................................................117
Saving a program........................................................................................................................117
Making a new program..............................................................................................................117
Loading a program.....................................................................................................................118
Deleting a program.....................................................................................................................118
Export as script ..........................................................................................................................119
Export Program File ...................................................................................................................119
9.5 USING TEMPLATES ..........................................................................................................................120
Saving as a template ...................................................................................................................120
Loading a template .....................................................................................................................121
Deleting a template .....................................................................................................................121
9.6 APPLYING PROGRAMS .....................................................................................................................122
9.7 MOVE COMMAND ..........................................................................................................................123
Selecting a movement method ....................................................................................................123
Radius of Linear .........................................................................................................................125
Don’t stop at this point ..............................................................................................................125
Blending......................................................................................................................................125
Advanced....................................................................................................................................127
Setting the coordinates for movement ........................................................................................127
Displaying as groups...................................................................................................................128
9.8 IF COMMAND.................................................................................................................................129
9.9 LOOP COMMAND .........................................................................................................................130
9.10 SWITCH COMMAND .....................................................................................................................131
9.11 WAIT COMMAND..........................................................................................................................132
9.12 SET COMMAND .............................................................................................................................133
9.13 FOLDER ..........................................................................................................................................134
Change Programed Icons into Folder .........................................................................................134
Create New Folder .....................................................................................................................134
9.14 MESSAGE........................................................................................................................................135
Output format ............................................................................................................................135

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Message operation......................................................................................................................135
Message format ..........................................................................................................................136
Select message.............................................................................................................................136
9.15 PATTERN COMMAND ..................................................................................................................137
Pattern types ...............................................................................................................................137
Setting the pattern coordinates ...................................................................................................138
Setting repeat counts...................................................................................................................138
Advanced commands for patterns ..............................................................................................139
Setting pattern points..................................................................................................................140
9.16 USING A SUB PROGRAM ..................................................................................................................141
Making a sub program...............................................................................................................141
Saving and loading a sub program .............................................................................................142
Entering a sub program ..............................................................................................................142
9.17 CONVEYOR ....................................................................................................................................144
Conveyor Setting .......................................................................................................................144
Conveyor Start Options.............................................................................................................145
Setting Conveyor Command.....................................................................................................145
9.18 VISION COMMAND .......................................................................................................................146
Setting basic options ...................................................................................................................146
Setting the movement speed........................................................................................................146
Setting the movement location....................................................................................................147
9.19 THREAD .........................................................................................................................................148
Thread Tab.................................................................................................................................148
Thread Creation .........................................................................................................................148
Event Tab ...................................................................................................................................149
9.20 SCRIPT ............................................................................................................................................150
Script Viewer ..............................................................................................................................150
9.21 PATH COMMAND ...........................................................................................................................151
Recording Paths..........................................................................................................................151
CHAPTER 10 STARTING THE ROBOT ..............................................................................................................153
Turning ON/OFF the robot .......................................................................................................154
Monitoring .................................................................................................................................154
Checking and setting the robot operation data ..........................................................................155
Operating the robot....................................................................................................................155
Locking Screen ...........................................................................................................................157
CHAPTER 11 MONITORING ...........................................................................................................................158
11.1 MONITORING THE ROBOT..............................................................................................................158

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Monitoring the robot positions ..................................................................................................158
Checking the robot status...........................................................................................................159
11.2 MONITORING INPUTS/OUTPUTS .....................................................................................................159
Monitoring controller inputs/outputs.........................................................................................160
Monitoring tool inputs/outputs..................................................................................................161
11.3 UTILIZATION ..................................................................................................................................162
CHAPTER 12 DEVICE SETTING .......................................................................................................................163
12.1 CONFIGURING MODBUS TCP .......................................................................................................163
Registering Devices .....................................................................................................................164
Editing/copying the device settings.............................................................................................165
Registering I/O ...........................................................................................................................166
Viewing the communication status.............................................................................................168
Viewing and setting the I/O values.............................................................................................168
Editing I/O settings.....................................................................................................................169
Deleting I/O................................................................................................................................169
12.2 USING A VISION SYSTEM .................................................................................................................170
12.3 ADDING AND SETTING VISION EQUIPMENT ......................................................................................171
Adding a vision equipment .........................................................................................................171
Setting a vision equipment..........................................................................................................171
12.4 SETTING VISION WORKSPACE .........................................................................................................173
Adding Vision Workspace..........................................................................................................173
Understanding rotation offsets....................................................................................................174
CHAPTER 13 ENVIRONMENT SETTING ..........................................................................................................176
13.1 GENERAL SETTING..........................................................................................................................176
13.2 NETWORK SETTING ........................................................................................................................177
CHAPTER 14 TURNING OFF THE SYSTEM.......................................................................................................178
14.1 SHUTTING DOWN THE OPERATION SOFTWARE ...............................................................................178
14.2 TURNING OFF CONTROLLERS .........................................................................................................178
CHAPTER 15 MAINTENANCE .........................................................................................................................179
15.1 INSPECTION ITEMS AND PERIODS ....................................................................................................179
15.2 CHECKING THE ROBOT ARM ..........................................................................................................180
Inspection period ........................................................................................................................180
Checking and cleaning the robot arm.........................................................................................180
15.3 CHECKING THE CONTROLLER ........................................................................................................180
Inspection period ........................................................................................................................180
Checking and cleaning the controller .........................................................................................180

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Cleaning and replacing the filter.................................................................................................181
15.4 VIEWING AND MANAGING LOGS ....................................................................................................182
Deleting Logs..............................................................................................................................182
Exporting Logs ...........................................................................................................................182
15.5 MANAGING THE ROBOT SYSTEM CONFIGURATION.........................................................................183
Packaging posture.......................................................................................................................183
Factory reset ...............................................................................................................................184
Use Default Program ..................................................................................................................184
Exporting the configurations ......................................................................................................184
Importing the configurations ......................................................................................................185
15.6 SOFTWARE UPDATE.........................................................................................................................187
Cautions during update ..............................................................................................................187
Updating software ......................................................................................................................187
APPENDIX A WARRANTY ..............................................................................................................................189
Warranty ....................................................................................................................................189
Warranty period .........................................................................................................................189
Limitation of Liability.................................................................................................................189
APPENDIX B CERTIFICATION .........................................................................................................................190
Safety .........................................................................................................................................190
MD(Machinery Directive) ..........................................................................................................191
LVD(Low Voltage Directive)......................................................................................................192
EMC (Electro Magnetic Compatibility.......................................................................................193
APPENDIX C DIMENSIONS FOR INSTALLATION .............................................................................................194
APPENDIX D TOOL FLANGE CROSS SECTION .................................................................................................195
APPENDIX E PORT PIN MAP .........................................................................................................................196
APPENDIX F SYSTEM SPECIFICATIONS ..........................................................................................................197
APPENDIX G STOPPING TIME AND DISTANCE ...............................................................................................198

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

Chapter 1 Product Overview
14
Safe collaboration
Using the various safety features, users can safely work next to the robot without using
additional safety tools or devices.
The robot is automatically stopped when it detects an impact, so as long as the working
range of the robot and the user are guaranteed, it can be installed anywhere for safe use.

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
8 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
Others
8 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
Parts and joints
➊ Tool Flange ➎
Lower Arm ➒ J1
➋
J6 Wrist3 ➏ Elbow ➓ Base
➌J5 Wrist2 ➐J3
➍
J4 Wrist1 ➑ J2 Shoulder

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
.
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 connector
Teaching pendant connector
Power button
AC power socket