Hanwha HCR-5 User manual

HCR-5
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.(https://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 .................................................................................................................... 15
1.1 COLLABORATIVE ROBOT SYSTEM......................................................................................................15
Easy setting...................................................................................................................................15
Flexible rearrangement .................................................................................................................15
Safe collaboration.........................................................................................................................16
1.2 SYSTEM COMPONENTS .....................................................................................................................17
1.3 BASIC SYSTEM CONFIGURATION .......................................................................................................18
1.4 OVERVIEW OF ROBOT ARMS.............................................................................................................19
1.5 OVERVIEW OF ROBOT CONTROLLER ................................................................................................21
Front.............................................................................................................................................21
Bottom..........................................................................................................................................22
1.6 OVERVIEW OF TEACHING PENDANT..................................................................................................23
Front.............................................................................................................................................23
Rear ..............................................................................................................................................24
1.7 AXIAL COORDINATES AND OPERATIONAL RANGE ............................................................................25
1.8 ROBOT'S WORKING RANGE ..............................................................................................................27
1.9 MAXIMUM LOAD CAPACITY FOR THE TOOL.......................................................................................28
CHAPTER 2 SAFETY .......................................................................................................................................... 29
2.1 SAFETY MARKS IN THE USER MANUAL..............................................................................................29
2.2 GENERAL SAFETY CAUTIONS ............................................................................................................30
2.3 INTENDED USE..................................................................................................................................31
2.4 POTENTIAL DANGERS .......................................................................................................................32
2.5 LIMITATION OF LIABILITY .................................................................................................................32
2.6 TRANSPORTATION ............................................................................................................................33
2.7 EMERGENCY STOP ............................................................................................................................34
Using emergency stop ...................................................................................................................34
Canceling emergency stop ............................................................................................................34
2.8 SAFETY FENCE ..................................................................................................................................35
2.9 LIMITS OF SPEED AND ROTATIONAL ANGLES ....................................................................................35
2.10 OPERATING ROBOTS WITHOUT DRIVING POWER ..............................................................................35
2.11 SAFETY CONTROLLER.......................................................................................................................35

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2.12 RISK ASSESSMENT .............................................................................................................................35
CHAPTER 3 INSTALLATION ............................................................................................................................... 37
3.1 INSTALLATION LOCATIONS ...............................................................................................................37
3.2 INSTALLATION TYPES........................................................................................................................38
3.3 FIXING ROBOTS ................................................................................................................................40
3.4 CONNECTING TOOLS TO ROBOTS.....................................................................................................41
3.5 CONNECTING CABLES.......................................................................................................................42
Connecting the teaching pendant to the robot controller.............................................................42
Connecting the robot arm to the robot controller........................................................................42
Connecting the power supply to the robot controller...................................................................43
3.6 FIXING THE CONTROLLER BOX ........................................................................................................44
3.7 OVERVIEW OF CONTROLLER I/O......................................................................................................45
3.8 COMMON SPEC FOR DIGITAL I/O .....................................................................................................45
3.9 CONFIGURING THE SAFETY INPUT .....................................................................................................48
Initial safety configuration ............................................................................................................49
Connecting the emergency stop button ........................................................................................50
Safety protection stop and restart.................................................................................................50
3.10 CONFIGURING THE GENERAL DIGITAL I/O .......................................................................................51
Load control with digital outputs.................................................................................................51
Digital input control using buttons...............................................................................................52
Communicating with other equipment or PLC ............................................................................52
3.11 CONFIGURING THE GENERAL ANALOG I/O ......................................................................................53
Analog output...............................................................................................................................54
Analog input.................................................................................................................................54
CHAPTER 4 GETTING STARTED ......................................................................................................................... 55
4.1 TURNING ON THE ROBOT CONTROLLER...........................................................................................55
4.2 TURNING ON THE TEACHING PENDANT............................................................................................56
CHAPTER 5 SOFTWARE OVERVIEW .................................................................................................................. 57
5.1 MENU OVERVIEW.............................................................................................................................57
Expanding menu...........................................................................................................................57
Robot Operation ..........................................................................................................................57
Programming ................................................................................................................................57
Monitoring ...................................................................................................................................58
Robot Setting................................................................................................................................58
Safety Setting ................................................................................................................................58
Device Setting ...............................................................................................................................58

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Management.................................................................................................................................58
SW Configuration.........................................................................................................................58
Message ........................................................................................................................................58
Manual Move...............................................................................................................................58
5.2 3D PREVIEW SCREEN ........................................................................................................................59
Screen display setting button ........................................................................................................59
Robot task control button............................................................................................................60
5.3 MANUAL MOVE SCREEN ..................................................................................................................61
5.4 VIRTUAL KEYPAD..............................................................................................................................63
Text keypad..................................................................................................................................63
Number keypad............................................................................................................................64
Expression keypad........................................................................................................................64
CHAPTER 6 REGISTERING ROBOTS AND USERS ................................................................................................ 66
6.1 MANAGING ROBOTS.........................................................................................................................66
Registering robots.........................................................................................................................67
Modifying the robot name............................................................................................................67
Registering Force Torque Sensor ..................................................................................................67
6.2 MANAGING USERS............................................................................................................................69
Adding users and setting authorities.............................................................................................69
Menu available to each authority.................................................................................................70
6.3 LOGIN/LOGOUT ...............................................................................................................................71
Logging in.....................................................................................................................................71
Logging out ..................................................................................................................................72
6.4 CHECKING STATUS............................................................................................................................72
Checking Robot Status................................................................................................................72
Checking errors............................................................................................................................72
Checking the software version....................................................................................................73
CHAPTER 7 SETTING ROBOTS ........................................................................................................................... 74
7.1 SETTING THE ROBOT INSTALLATION ANGLES....................................................................................74
7.2 SETTING TCP ...................................................................................................................................75
Creating a new TCP profile ..........................................................................................................76
Calculating the TCP position........................................................................................................78
Setting the TCP orientation ..........................................................................................................81
Changing the TCP profile name ...................................................................................................83
Editing the TCP profile.................................................................................................................83
Deleting the TCP profile ...............................................................................................................84

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7.3 SETTING INPUTS/OUTPUTS................................................................................................................85
Types of digital I/O ......................................................................................................................85
Editing the digital inputs settings..................................................................................................86
Editing the digital outputs settings................................................................................................86
Types of analog I/O .....................................................................................................................87
Editing the analog I/O setting.......................................................................................................88
7.4 COORDINATES..................................................................................................................................89
Registering points .........................................................................................................................89
Registering line coordinates ..........................................................................................................90
Registering plane coordinates .......................................................................................................90
7.5 SETTING GLOBAL VARIABLES ............................................................................................................91
7.6 I/O BIT OPERATION .........................................................................................................................92
Add/Delete ...................................................................................................................................92
I/O bit operation settings .............................................................................................................92
CHAPTER 8 SAFETY SETTINGS........................................................................................................................... 93
8.1 LIMITING ROBOT MOVEMENT..........................................................................................................93
Default settings .............................................................................................................................94
Manual setting method.................................................................................................................94
8.2 SETTING SAFETY BOUNDARIES ..........................................................................................................97
Adding safety boundary planes.....................................................................................................97
Viewing safety boundary planes ...................................................................................................98
Applying safety boundaries...........................................................................................................99
Changing the name of safety boundaries....................................................................................100
Deleting safety boundary settings ...............................................................................................100
8.3 SETTING TOOL BOUNDARIES...........................................................................................................102
Adding Tool Safety Boundary Surfaces ......................................................................................102
Setting Tool Safety Boundary Surfaces .......................................................................................103
Applying Tool Safety Boundary Surfaces ...................................................................................103
8.4 SETTING REDUNDANT I/O..............................................................................................................104
8.5 SETTING SAFEGUARD I/O................................................................................................................106
8.6 EXCEEDING SAFETY LIMIT OF JOINTS..............................................................................................107
CHAPTER 9 PROGRAMMING ...........................................................................................................................108
9.1 HOW TO USE COMMANDS ..............................................................................................................108
Selecting a flowchart...................................................................................................................108
Type of commands .....................................................................................................................109
Additional Commands................................................................................................................110

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Entering commands....................................................................................................................111
Check Icon Status.......................................................................................................................111
Changing command names ........................................................................................................111
Deleting commands ....................................................................................................................112
Searching Commands .................................................................................................................112
Skipping Commands...................................................................................................................112
Tree ............................................................................................................................................113
9.2 SETTING VARIABLES........................................................................................................................114
Adding variables .........................................................................................................................114
Modifying variables....................................................................................................................115
Deleting variables .......................................................................................................................115
Variable Monitoring...................................................................................................................115
9.3 EDITING PROGRAMS........................................................................................................................116
Overview of edit menu ...............................................................................................................116
Example of program editing .......................................................................................................117
Undo Function............................................................................................................................118
9.4 MANAGING A PROGRAM ................................................................................................................119
Saving a program........................................................................................................................119
Making a new program..............................................................................................................119
Loading a program.....................................................................................................................120
Deleting a program.....................................................................................................................120
Export as script ..........................................................................................................................121
Export Program File ...................................................................................................................121
9.5 USING TEMPLATES ..........................................................................................................................122
Saving as a template ...................................................................................................................122
Loading a template .....................................................................................................................123
Deleting a template .....................................................................................................................123
9.6 APPLYING PROGRAMS .....................................................................................................................124
9.7 MOVE COMMAND ..........................................................................................................................125
Selecting a movement method ....................................................................................................125
Radius of Linear .........................................................................................................................127
Don’t stop at this point ..............................................................................................................127
Blending......................................................................................................................................127
Advanced....................................................................................................................................129
Setting the coordinates for movement ........................................................................................129
Displaying as groups...................................................................................................................130
9.8 IF COMMAND.................................................................................................................................131

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9.9 LOOP COMMAND .........................................................................................................................132
9.10 SWITCH COMMAND .....................................................................................................................133
9.11 WAIT COMMAND..........................................................................................................................134
9.12 SET COMMAND .............................................................................................................................135
9.13 FOLDER ..........................................................................................................................................136
Change Programed Icons into Folder .........................................................................................136
Create New Folder .....................................................................................................................136
9.14 MESSAGE........................................................................................................................................137
Output format ............................................................................................................................137
Message operation......................................................................................................................137
Message format ..........................................................................................................................138
Select message.............................................................................................................................138
9.15 PATTERN COMMAND ..................................................................................................................139
Pattern types ...............................................................................................................................139
Setting the pattern coordinates ...................................................................................................140
Setting repeat counts...................................................................................................................140
Advanced commands for patterns ..............................................................................................141
Setting pattern points..................................................................................................................142
9.16 USING A SUB PROGRAM ..................................................................................................................143
Making a sub program...............................................................................................................143
Saving and loading a sub program .............................................................................................144
Entering a sub program ..............................................................................................................144
9.17 CONVEYOR ....................................................................................................................................146
Conveyor Setting .......................................................................................................................146
Conveyor Start Options.............................................................................................................147
Setting Conveyor Command.....................................................................................................147
9.18 VISION COMMAND.......................................................................................................................148
Setting basic options ...................................................................................................................148
Setting the movement speed........................................................................................................148
Setting the movement location....................................................................................................149
9.19 THREAD .........................................................................................................................................150
Thread Tab.................................................................................................................................150
Thread Creation .........................................................................................................................150
Event Tab ...................................................................................................................................151
9.20 SCRIPT ............................................................................................................................................152
Script Viewer ..............................................................................................................................152
9.21 PATH COMMAND ...........................................................................................................................153

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Recording Paths..........................................................................................................................153
CHAPTER 10 STARTING THE ROBOT ..................................................................................................................155
Turning ON/OFF the robot .......................................................................................................156
Monitoring .................................................................................................................................156
Checking and setting the robot operation data ..........................................................................157
Operating the robot....................................................................................................................157
Locking Screen ...........................................................................................................................159
CHAPTER 11 MONITORING ...............................................................................................................................160
11.1 MONITORING THE ROBOT..............................................................................................................160
Monitoring the robot positions ..................................................................................................160
Checking the robot status...........................................................................................................161
11.2 MONITORING INPUTS/OUTPUTS .....................................................................................................161
Monitoring controller inputs/outputs.........................................................................................162
Monitoring tool inputs/outputs..................................................................................................163
11.3 UTILIZATION ..................................................................................................................................164
CHAPTER 12 DEVICE SETTINGS..........................................................................................................................165
12.1 CONFIGURING MODBUS TCP .......................................................................................................165
Registering Devices .....................................................................................................................166
Editing/copying the device settings.............................................................................................167
Registering I/O ...........................................................................................................................168
Viewing the communication status.............................................................................................170
Viewing and setting the I/O values.............................................................................................170
Editing I/O settings.....................................................................................................................171
Deleting I/O................................................................................................................................171
12.2 USING A VISION SYSTEM .................................................................................................................172
12.3 ADDING AND SETTING VISION EQUIPMENT ......................................................................................173
Adding a vision equipment .........................................................................................................173
Setting a vision equipment..........................................................................................................173
12.4 SETTING VISION WORKSPACE .........................................................................................................175
Adding Vision Workspace..........................................................................................................175
Understanding rotation offsets....................................................................................................176
CHAPTER 13 ENVIRONMENT SETTING ..............................................................................................................178
13.1 GENERAL SETTING..........................................................................................................................178
13.2 NETWORK SETTING ........................................................................................................................179
CHAPTER 14 TURNING OFF THE SYSTEM...........................................................................................................180

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14.1 SHUTTING DOWN THE OPERATION SOFTWARE ...............................................................................180
14.2 TURNING OFF CONTROLLERS.........................................................................................................180
CHAPTER 15 MAINTENANCE .............................................................................................................................181
15.1 INSPECTION ITEMS AND PERIODS ....................................................................................................181
15.2 CHECKING THE ROBOT ARM ..........................................................................................................182
Inspection period ........................................................................................................................182
Checking and cleaning the robot arm.........................................................................................182
15.3 CHECKING THE CONTROLLER ........................................................................................................182
Inspection period ........................................................................................................................182
Checking and cleaning the controller .........................................................................................182
Cleaning and replacing the filter.................................................................................................183
15.4 VIEWING AND MANAGING LOGS ....................................................................................................184
Deleting Logs..............................................................................................................................184
Exporting Logs ...........................................................................................................................184
15.5 MANAGING THE ROBOT SYSTEM CONFIGURATION.........................................................................185
Packaging posture.......................................................................................................................185
Factory reset ...............................................................................................................................186
Use Default Program ..................................................................................................................186
Exporting the configurations ......................................................................................................186
Importing the configurations ......................................................................................................187
15.6 SOFTWARE UPDATE.........................................................................................................................189
Cautions during update ..............................................................................................................189
Updating software ......................................................................................................................189
APPENDIX A WARRANTY ..................................................................................................................................191
Warranty ....................................................................................................................................191
Warranty period .........................................................................................................................191
Limitation of Liability.................................................................................................................191
APPENDIX B CERTIFICATION .............................................................................................................................192
Safety .........................................................................................................................................192
MD(Machinery Directive) ..........................................................................................................194
LVD(Low Voltage Directive)......................................................................................................195
EMC (Electro Magnetic Compatibility) .....................................................................................196
Cleanroom-Body .......................................................................................................................197
Cleanroom-Controller ...............................................................................................................198
APPENDIX C DIMENSIONS FOR INSTALLATION .................................................................................................199

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APPENDIX D TOOL FLANGE CROSS SECTION......................................................................................................200
APPENDIX E PORT PIN MAP..............................................................................................................................201
APPENDIX F SYSTEM SPECIFICATIONS ..............................................................................................................202
APPENDIX G STOPPING TIME AND DISTANCE ...................................................................................................203

Chapter 1 Product Overview
15
Chapter 1 Product Overview
1.1 Collaborative Robot System
Hanwha Precision Machinery's collaborative robot, HCR-5 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
16
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
17
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
18
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
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
19
1.4 Overview of Robot Arms
Parts and joints
➊ Tool Flange ➎Lower Arm ➒J2 Shoulder
➋
J6 Wrist3 ➏ Elbow ➓ J1
➌J5 Wrist2 ➐J3 Base
➍
J4 Wrist1 ➑ Upper Arm

Chapter 1 Product Overview
20
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 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.