Hyundai YL005 User manual

Maintenance Manual
for Collaborative Robot

Maintenance Manual for Collaborative Robot
Contents_3
About this manual
This manual describes the safety, installation, use, and maintenance methods of collaborative robots manufactured
by Hyundai Robotics.
Before using the product, read and fully understand the content of this manual. In addition, keep this manual at a
handy place so that it can be read any time when necessary.
This manual may be provided to customers who purchase products of Hyundai Robotics, or may be used as a
material for internal training programs.
As this manual has been prepared based on standard specifications, it may not apply equally to all models that you
purchase. In addition, the details and specifications of this manual are subject to changes for improving product
performance without notice, and Hyundai Robotics will not take responsibilities for any consequences of incorrect
details, typos, or omissions of this manual. For detailed information on revisions, please visit our website
(www.hyundai-robotics.com).
Copyright
All the programs, files, and contents relating to this product and manual are protected by the Copyright Act and a
confidentiality agreement. Any use, reproduction, and disclosure or distribution of this manual to third parties not
explicitly permitted by Hyundai Robotics are strictly prohibited.
Copyright ⓒ2020 HYUNDAI ROBOTICS. All rights reserved.
Notation rules
This manual utilizes the following expression rules and safety directions for easy understanding.
Description by figures
Figures are used for easy understanding of how to operate the product and for describing screens. When a
description is made by a figure, the pertaining part is marked with the figure number that describes the part as
shown in the following:
GUI (Graphical User Interface)
In regard to GUI, any menu name or a button name will be in brackets ([]), and in the bold type. When
multiple menus need to be selected in the listed order, the menu names will be separated by the symbol, >.
Menu having a title: On the initial screen of the manual or the automatic mode, select the [Menu] button.
Multiple menus: In the initial screen of the manual mode, select the [Setting] button > [5: Reset > 7: Unit
Setting] menu.
Manipulation key notation method
Any key to be pressed in the functional manipulation area of the teach pendant will be in angle brackets (< >),
and in the bold type.

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Pressing the <Start> key will initiate the automatic execution of the sequence programmed into the robot.
Cross references
This provides the shortcut to the related information in the manual. Cross references will be in quotation marks,
and in the bold type.
For details of making changes in date and time information, see “4.5 Date and time setting.”
References
Useful or additional information on using the product will be provided as follows:
Remarks
Blinking of the icon in the status bar indicates the engineer mode.

Maintenance Manual for Collaborative Robot
Contents_5
Safety precautions
For ensuring proper product use, user safety, and for preventing property damages, make sure to read and fully
understand the following precautions before using the product.
Danger
Danger
Impending risk: If not conformed to, operator deaths or severe injuries may occur.
Carry out risk assessment on the entire system, not the individual devices. Connecting other devices to the
product may increase the risk level of the product or create new risks. If the devices of the robot
integrated system have different risk levels, prepare safety devices based on the device of the highest risk
level in preparedness for risks.
In installing the robot product and other devices, make sure to read, fully understand, and conform to the
product installation instructions described in the manual.
In case of any issues of the product such as faults and damages, immediately stop using the product, and
contact our Customer Support Team.
Warning
Warning
Potential risk: If not conformed to, operator injuries or property damages including serious
product damages may occur.
Take adequate safety measures according to the result of risk assessment, and accurately assign the safe
range of robot installation. During the robot operation, product damages or user injuries may occur.
Persons who manufacture robot application systems or use the robot must read and fully understand the
manual, and take training in robot operation.
For the safety of operators and users, prepare adequate safety facilities such as safety fences before
installing the product.
Secure sufficient space so that the robot arm can move freely. During the robot operation, product
damages or user injuries may occur.
Fasten locking bolts to the specified torque according to the specification sheet. Lose bolts may lead to
damages of the robot due to falling from the installation position.
Pay attention to the product connections (power and cables) so that no conducting substances such as
liquid, dust, and metal particles infiltrate. Do not poke the connection with sharp objects, or apply
excessive force during cable connection. Corrosion or temporary short circuits of connectors may lead to
product explosion or fires.
Check the wiring specification, and connect devices with terminals that are suitable for device types. In
particular, make sure to connect safety devices to dedicated terminals because connecting them to general
terminals does not guarantee safety functions.
Never use damaged cables, and do not disconnect cables while the product is in operation. It may lead to
electric shocks, fires, faults, and injuries.
Long-time use of the product may generate overheating and lead to injuries such as burns. In the event it
is necessary to touch the product, sufficiently cool down the product by powering it off and leaving it for
at least one hour.

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Never arbitrarily install, modify, disassemble or repair the product. It may lead to faults and accidents.
Hyundai Robotics will not take responsibilities for product damages caused by such arbitrary actions.
Caution
Caution
Minor risk: If not conformed to, minor operator injuries or property damages including
product damages may occur.
Do not arbitrarily install, modify, disassemble or repair the product. It is prohibited for persons other than
experts from Hyundai Robotics to modify the product or attach parts to the product. Product faults caused
by it will void free-of-charge services and warranty services.
In the event it is necessary to install or repair the product, contact our Customer Support Team to consign
the work to experts.
Do not install or use the product at a place having much dust or dirt. Dust or foreign matters may lead to
product faults or malfunction.
Do not install or use the product at a place of magnetism, or a place which is affected by magnetism, or a
place of electromagnetic interferences. Magnetism may lead to product damages or malfunction.
In operating the product, do not wear loose outfit or accessories. If you wear long hair, tie it at the back
of the head so that it is not entangled between joints and the like of the robot.
While the product is in operation, do not enter its operating range or touch the robot. It may lead to
injuries.
Transport the product as it is packaged for preventing product damages, and store it at a dry and low-
humidity place. Storing it at a humid place may lead to product damages or faults due to moisture
infiltration.
Store the product at a place clean, cool, dry, and free from high variation in temperature and humidity.
The product should be moved by two or more persons, maintaining the correct posture. If not, the
persons may be subject to physical injuries in the waist, arms, legs and the like.
In moving the product by means of a lifting equipment, conform to the local and national safety
regulations and the instructions for equipment use.
Before moving the product, read and conform to the moving instructions specified in the manual. Hyundai
Robotics will not take responsibilities for product damages caused by customer's product transportation.

Maintenance Manual for Collaborative Robot
Contents_7
Contents
About this manual 3
Copyright 3
Notation rules 3
Safety precautions 5
1. Safety 9
1.1 Safety requirements 9
1.1.1 Applicable standards 9
1.1.2 Safety performance 10
1.2 Safety measures 11
1.2.1 Safety functions 11
1.2.2 Safety training 12
1.2.3 Safety labels 12
1.2.4 Emergency stop 13
1.3 Risk assessment 15
1.4 Potential risks 16
1.5 Validity and responsibilities 16
2. Introduction to the product 18
2.1Intended uses of the product 18
2.2 Product components 19
2.3 Part names 20
2.3.1 Collaborative robot 20
2.3.2 Controller 21
2.3.3 Teach pendant 22
2.4 Nameplate 23
3. Product installation 25
3.1 Environment of installation and
preparation 25
3.1.1 Environments of installation and use
25
3.1.2 Spaces of robot systems 26
3.1.3 Allowable limit of wrist axis load 29
3.1.4 Payload 29
3.2 Product installation 31
3.2.1 Composition of robot systems 31
3.2.2 Robot and controller installation 31
3.2.3 Tool connection 33
3.2.4 Wiring 35
3.2.5 Powering on 36
3.3 Robot interface 37
3.3.1 Tool flange connection point 37
3.3.2 External device interface 38
3.4 Stopping distance and time 45
3.4.1 STOP0 45
3.4.2 STOP1 46
3.5 Safety setting 48
3.6 Programming and restarting 48
3.7 Axis restriction devices 48
3.8 Movement without driving power 48
3.9 Other safety precautions 49
4. Maintenance 50
4.1Checks on the collaborative robot 50
4.1.1 Check sheet 51
4.1.2 Wiring check 52
4.1.3 Bolt check 52
4.2 Maintenance of the collaborative robot 53
4.2.1 Replacement of internal wiring 53
4.2.2 Replacement of the integrated
driving module 53
4.2.3 Encoder backup battery
replacement 58
4.2.4 Grease replacement 59
4.3 Controller check and maintenance 60
4.3.1 Internal structure 60
4.3.2 Safety control module 61
4.3.3 Power pre-charge module (PPM) 68
4.3.4 Regenerative discharge module
(RDM) 69
4.3.5 Microcomputer module 71
4.3.6 Power supply 73
4.3.7 Teach pendant 73
4.3.8 PCI communication card (optional)74
5. Moving and storing 78
5.1 Moving method 78
5.1.1 Recommended posture 80
5.1.2 Packaging box 80
5.1.3 Cautions 80
5.2 Storing method 81
5.3 Disposal 81
6. Appendix 83
6.1 Block diagrams 83
6.1.1 YL012 S-axis 83
6.1.2 YL012 H-axis 84
6.1.3 YL012 V-axis 85
6.1.4 YL012 R2-axis 86
6.1.5 YL012 B-axis 87
6.1.6 YL012 R1-axis 88
6.1.7 YL012 tool flange 89
6.1.8 Power connector 89
6.2 System specifications 90
6.2.1 Collaborative robot 90
6.2.2 Controller 91

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6.2.3 Teach pendant 91
Certificates 92
Warranty 93

Maintenance manual for Collaborative Robot
Hyundai Robotics Safety | Safety requirements_9
Safety
1. Safety
1.1 Safety requirements
1.1.1 Applicable standards
This product has been designed and manufactured in compliance with ISO 10218-1, a safety standard of industrial
robots, and ISO/TS 15066, a standard specifying safety requirements for collaborative operation. The safety
standards applicable to this product are as follows:
ISO 10218-1:2011 Robots and robotic devices - Safety requirements for industrial robots - Part 1: Robots
ISO 10218-2:2011 Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot
systems and integration
ISO/TS 15066:2016 Robots and robotic devices - Safety requirements - Industrial collaborative workspace
IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 1: General requirements
IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems
IEC 61508-3:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 3: Software requirements
IEC 61508-4:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 4: Definitions and abbreviations
IEC 61508-5:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 5: Examples of methods for the determination of safety integrity levels
IEC 61508-6:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 6: Guidelines on the application of IEC 61508-2 and IEC 61508-3
IEC 61508-7:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems -
Part 7: Overview of techniques and measures
IEC 61800-5-1:2007/A1:2017 Adjustable speed electrical power drive systems - Part 5-1: Safety requirements -
Electrical, thermal and energy
IEC 61800-5-2:2015 Adjustable speed electrical power drive systems - Part 2: General requirements - Rating
specifications for low voltage adjustable speed a.c. power drive systems
ISO 13849-1:2015 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for
design
ISO 13849-2:2012 Safety of machinery - Safety-related parts of control systems - Part 2: Validation
IEC 62061:2005/A2:2015 Safety of machinery. Functional safety of safety-related electrical, electronic and
programmable electronic control systems
IEC 61784-3:2016 Industrial communication networks - Profiles - Part 3: Functional safety fieldbuses - General
rules and profile definitions
IEC 61800-3:2017 Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test
methods

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10_Safety | Safety requirements Hyundai Robotics
IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) - Part 6-7: Generic standards - Immunity requirements
for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations
IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use. EMC requirements. Part
3-1: Immunity requirements for safety-related systems and for equipment intended to perform safety-related
functions (functional safety) - General industrial applications
1.1.2 Safety performance
The safety performance of the collaborative robot is as follows:
Category
Safety performance
Applicable standards
HFT
1
IEC 61508/62061/61800-5-2
SIL (Safety Integrity Level)
2
Category
3
ISO 13849-1
PL (Performance Level)
d

Maintenance manual for Collaborative Robot
Hyundai Robotics Safety | Safety measures_11
Safety
1.2 Safety measures
This section describes the safety functions embedded into the product, and the measures for ensuring the safety of
users and operators.
1.2.1 Safety functions
The collaborative robot is intended to carry out collaborative works based on the following safety functions. For the
details of the safety functions, see the “Safety Function Manual for Collaborative Robots.”
STO: Safe Torque Off
SS1: Safe Stop 1
SS2: Safe Stop 2
EM (Emergency) Stop
Protective Stop
SBC: Safe Brake Control
Safety Outputs
Safety Inputs
SOS: Safe Operating Stop
Joint-SLP, Joint Angle Monitoring
Joint-SLS, Joint Angular Speed Monitoring
Joint- SLT, Joint Torque Monitoring
Collision Detection
TCP-SLP, TCP Position Monitoring
TCP Orientation Monitoring
TCP-SLS, TCP Speed Monitoring
TCP Force Monitoring
Momentum Monitoring
Power Monitoring

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12_Safety | Safety measures Hyundai Robotics
1.2.2 Safety training
In order to effectively use the product functions, the user must read and fully understand the manual, and install,
use, and maintain the product in the proper manner. The product user will be responsible for having the full
knowledge of and conforming to the robot-related safety regulations of the locality in which the robot is installed
and used, and for the proper designing, installation, and operation of the safety devices that can guarantee the
safety of the workers of the robot system.
All the workers who install, use, and maintain the robot system must read and fully understand the manual. In
particular, they must be fully knowledgeable of the safety precautions ( ).
Hyundai Robotics establishes and implements plans for providing training in product installation, use, and
maintenance. Product operators and workers must take the relevant training programs before handling the
product.
Workers who are responsible for the robot's teaching and checkups must take a training program in robot use
and safety before handling the robot. The safety training program covers the following topics:
The concept of safety, and the purposes and functions of the safety devices
The procedures for handling the robot safely
The performance and potential risks of the robot and robot system
The works and the like relating to the application of specific robots
1.2.3 Safety labels
On the inside and outside of the controller, nameplates, warning signs, safety symbols and the like are attached.
Check the labels for ensuring safety.
Figure 1 Figure 2 Safety label attachment points: front (left) / top (center) / rear (right)
Front View
Top View
Rear View

Maintenance manual for Collaborative Robot
Hyundai Robotics Safety | Safety measures_13
Safety
Figure 3 Safety label attachment points: side (left) / inner side (right)
Warning
Never make behaviors that damage safety labels, such as moving the position of the nameplate,
warning signs, safety symbols, nomenclature markings, cable markings and the like attached to the
controller, or hiding them by putting paint or covers.
Caution
Indicate the robot installation areas and hazard areas with distinct shapes, color, or styles, so that
they are clearly distinguished from other facilities and equipment.
1.2.4 Emergency stop
The emergency stop function is actuated in emergency where a worker or object enters a hazard area. All the
emergency stop switches are installed at places easily accessible from outside the safety areas.
When the emergency stop function is actuated, the robot will immediately stop moving in any case.
The servo system power of the robot will be cut off and the motor brake will be actuated.
On the teach pendant screen, an emergency stop massage will appear.
1.2.4.1 Emergency stop switches
One emergency stop switch is installed each at the controller and the teach pendant. In case of emergency, press an
emergency stop switch.
Right-side View
Case Inside View

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14_Safety | Safety measures Hyundai Robotics
Figure 4 Emergency stop switches: controller (left) / teach pendant (right)
1.2.4.2 Connecting to emergency stop devices of external systems
In addition to the emergency stop switches installed by default, it is possible to add external emergency stop XL
devices according to site conditions and applications. For more details, see “3.3.2.3 Terminal block (TB3): common
safety signal I/O.”
(Terminal bock TBSDI)
1
External Emegency
Stop Devices
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Safety Control Module (SCM)
Figure 5 Connecting emergency stop device of a safety control module (SCM)
Note
See the details of “3.3.2.2 Terminal block (TB2): dedicated safety signal input” and “4.3.2 Safety
control module.”
Safety Control Module (SCM)
(Terminal bock TBSDI)
External Emergency Stop
Device

Maintenance manual for Collaborative Robot
Hyundai Robotics Safety | Risk assessment_15
Safety
1.3 Risk assessment
In composing a robot integrated system, risk assessment is so important a factor that most countries specify it as a
statutory requirement. Because safety assessments of robot installation vary depending on methods for integrating
robots into systems, the risks of robot integrated systems cannot be assessed only by robots themselves.
System administrators should carry out risk assessment on system composition and operation according to the
instructions specified in ISO 12100 and ISO 10218-2. The technical specifications of ISO/TS 15066 may be also
referred to.
Carry out risk assessment in consideration of the entire processes of the integrated system including robots. The
major objectives of risk assessment are as follows:
Basic setting of robot use and robot teaching
Problem diagnosis and maintenance
Normal operation of installed robots
After installing robots and composing the system, risk assessment must be carried out. In risk assessment, the major
points to be determined include the adequacy of the safety devices of robot integrated systems, and the necessity
for additional emergency stop devices or other safety devices.
It is very important to compose robot integrated systems based on the identification of adequate safety devices.
Compose robot integrated systems referring to the relevant details of the manual.
For collaborative robots, it is possible to set TCP speed, pressure, power, momentum, collision detection, limit values
of reduction ratio, and limit values of joint-specific angles, speeds, and torques. In addition, safety functions can be
composed by using safety-related I/Os. For more details for the composition of safety functions, see the “Safety
Function Manual for Collaborative Robots.”
In the [Safety functions] menu, the safety-related functions of the collaborative robot can be set, including the
following:
Force and power limits: Limit the force and pressure at which the robot should stop in case of collision between
the robot and an operator.
Momentum limits: Limit energy and impact load by decreasing the robot's motion speed in case of collision
between the robot and an operator.
Joint and TCP position limits: Limit the robot's motion so that it does not move to body parts such as the user's
neck or head.
TCP and tool posture limits: Limit motion to reduce risks relating to specific sections or characteristics of tools
and operating parts (e.g.: sharp points of tools or objects under operation).
Speed limits: Limit the speed of the robot at a low speed so that an operator can escape collision with the
robot.
In addition, safety-related functions can be composed by installing the robot at a specific location or using safety
I/Os.
The major categories of the risk assessment of robot integrated systems include the following:
Collision severity of robots
Collision probability of robots
Collision avoidance probability of robots

Hyundai Robotics
16_Safety | Potential risks Hyundai Robotics
In composing robot systems, if risk factors (e.g.: use of tools unintended for collaborative robots) are not sufficiently
removed by the robot’s safety functions, the necessity for additional protective devices can be identified in the risk
assessment.
1.4 Potential risks
In the risk assessment of a robot integrated system, if the assessment result indicates that risk factors are not
sufficiently removed only by the robot's safety functions, additional protective measures must be established.
In establishing additional protective measures, the following should be considered:
Finger pinching (entanglement) between the robot base and the installation support during installation
Injuries (such as poking and piercing) due to sharp edges or protruding parts of obstacles or tools in the
operating area
Injuries due to collision with the robot (such as bruises, falling, bone fractures)
Injuries due to obstacles around the robot (such as poking, piercing, and bone fractures)
Injuries due to loose connections
Injuries due to toxic or hazardous substances under work (such as skin damages, and breathing disorders)
Displacement of objects under work due to abrupt power shut-offs
Erroneous activation of emergency stop switches due to confusion with those of other equipment
Errors due to arbitrary modification of the settings of safety functions
Because the types of potential risks vary depending on system compositions, risk assessment must be carried out
before using a robot integrated system.
1.5 Validity and responsibilities
The user should conform to the safety requirements specified in the safety laws and regulations of the country and
locality in which the robot is installed and used. Responsibilities of suppliers and users of robot integrated systems
include but are not limited to the following:
Risk assessment of robot integrated systems
Addition or removal of safety devices according to the result of risk assessment
Checking that robot integrated systems are properly composed, installed and set
Establishment of the methods and instructions for using robot integrated systems, and provision of user training
Management of safety devices (prohibition of users from arbitrary modification and manipulation of safety
devices)
Provision of important pieces of information, contact addresses and the like relating to product use and safety
Provision of all types of technical documents including manuals
The safety-related content of this manual does not cover all the risk factors and situations that may occur during
product use.

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Hyundai Robotics Safety | Validity and responsibilities_17
Safety

Hyundai Robotics
18_Introduction to the product | Intended uses of the product Hyundai Robotics
2. Introduction to the product
This product, which is an industrial collaborative robot that can be used for moving objects or assembling parts by
using various tools, may be used only in environments that meet the requirements specified in this manual. This
product, which is manufactured for the purpose of collaborative works with persons, has safety functions that
enable collaborative works without physical protective devices.
Figure 6 Collaborative robot and controller
Caution
In composing a system linked with tools, objects under work, and other additional equipment, final
risk assessment must be carried out for verifying safety of the system before using it.
2.1 Intended uses of the product
This product may be used only for the specified intended uses. Use of this product for other purposes than the
intended uses will be considered as an inappropriate behavior. Hyundai Robotics will not take responsibilities for
injuries or property losses including product damages and faults caused by unintended uses of this product.
Examples of improper uses of this product include the following:
Using the product as a means of stepping on
Using the product for moving persons or animals
Using the product in areas relating to healthcare and human lives
Using the product in environments of explosion hazards
Using the product without carrying out risk assessment
Using the product in conditions where the requirements for the performance of safety functions are not met
Using the product at places where the performance and environmental requirements are not met
Using the product (e.g. for welding) at places where electromagnetic waves higher than those specified in the
international standard (IEC) are radiated

Maintenance manual for Collaborative Robot
Hyundai Robotics Introduction to the product | Product components_19
Introduction to the product
2.2 Product components
Upon purchasing the product, make sure to check that it includes all the components supposed to be supplied. If it
does not include any components, contact our Customer Support Team or make a query on our website
(www.hyundai-robotics.com).
Collaborative robot
Controller
Robot connection cables
Teach pendant
Power connector
User manual
Note
The available collaborative robot models are YL005, YL012, and YL015. This maintenance
manual describes the methods for composing, installing, using, and maintaining them based on
the YL012 model.
Partial details including components, product parts, and methods for using may be different
depending on collaborative robot models.
If you use a hand strap, you can use the teach pendant held to the hand without having it fall.
If you retain the packaging materials of the product, you may use them later for transporting
and storing it.

Hyundai Robotics
20_Introduction to the product | Part names Hyundai Robotics
2.3 Part names
Identifying the part names of the product is useful for finding out how to install and use it.
2.3.1 Collaborative robot
Figure 7 Layout of the collaborative robot (left) / axial motors (right)
Figure Major parts of the collaborative robot
No.
Name
Description
Tool flange
This mounts tools to the robot.
EtherCAT connector
This establishes communication with tools through EtherCAT-based terminals. For
more details of EtherCAT, see “3.3.1 Tool flange connection point.”
Tool I/O connectors
These control the motion of tools. For more details of the tool I/O, see “3.3.1 Tool
flange connection point.”
Air outlets
(YL012, YL015) These are used for moving various tools by connecting pneumatic
hoses (ø3.2, two pieces).
Hand-grip module
This is used for direct teaching.
Arm frame
Arm pipe
Wrist
Mechanical interface
Upper frame
Lower frame
Base body
S-axis motor
V-axis motor
H-axis motor
R1-axis motor
B-axis motor
R2-axis motor