JAKA JAKA Zu 7 User manual

JAKA ROBOTS
USER MANUAL
JAKA Zu®7

JAKA Zu®7 - V1.1 2
JAKA ROBOTS
USER MANUAL
JAKA Zu®7 - V1.1
Robot Serial Number:
Electrical Cabinet Serial Number:

JAKA Zu®7 - V1.1 3
CAUTION
The information contained in this manual is the exclusive property of JAKA
Robotics. (hereinafter referred to as JAKA), and shall not be reproduced or
transmitted without JAKA’s prior written approval.
JAKAreserves the right to regularly revise the contents contained in this manual without
prior notice.
JAKA will not be held liable for any mistakes in this manual or for any injury or death
resulting from the use of this manual and its product. Please carefully read this manual and
other related manuals before installing and using the product.
The pictures in this manual are for reference only, please refer to the actual product.
JAKA will not provide after-sales service for any transformation or disassembly of the
product.

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Contents
Preface ············································································································ 07
Product List········································································································· 07
Manual Instruction ································································································ 07
1 Safety ············································································································· 09
1.1 Introduction ···································································································· 09
1.2 Warning Sign Descriptions················································································· 09
1.3 Safety Precautions··························································································· 10
1.4 Warnings and Cautions····················································································· 11
1.5 Responsibilities and Risks ················································································· 12
1.6 Usage ··········································································································· 12
1.7 Emergency····································································································· 13
1.8 Movement Without Drive Power·········································································· 13
2 Precautions for Transportation and Handling ······················································· 14
3 Mechanical Interface························································································· 15
3.1 Robot workspace····························································································· 15
3.1.1 Robot dimensions ························································································· 15
3.1.2 Robot motion range······················································································· 16
3.2 Installation ····································································································· 16
3.2.1 General installation steps················································································ 16
3.2.2 Important safety instructions············································································ 17
3.2.3 Robot body installation ··················································································· 17
3.2.4 End tool installation ······················································································· 18
4 Electrical Interface···························································································· 19
4.1 Introduction ···································································································· 19
4.2 Warnings and Cautions····················································································· 19
4.3 Controller I/O·································································································· 19
4.3.1 Digital Input(DI)····························································································· 21
4.3.2 Digital Output(DO)························································································· 21
4.3.3 Analog Input(AI)···························································································· 21
4.3.4 Status description·························································································· 22

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4.4 Ethernet ········································································································ 22
4.5 Emergency Stop Button Box ·············································································· 23
4.6 Power Connection ··························································································· 24
4.7 Robot Connection···························································································· 24
5 Safety Relating Functions and Interfaces····························································· 26
5.1 Safety Functions······························································································ 26
5.2 Collision Detecting ··························································································· 27
5.3 End Effector Buttons························································································· 27
6 Maintenance and Repairing················································································ 28
6.1 Safety Instructions···························································································· 28
6.2 Overhaul Project and Cycle················································································ 29
6.3 Parts Replacement and Preservation ··································································· 31
6.3.1 Filter cleaning and replacement········································································ 32
6.3.2 Joints replacement························································································· 32
6.3.3 Parts preservation ························································································· 32
6.4 Service Commitment ························································································ 33
7 Design Criterion ······························································································· 35
8 Warranty·········································································································· 36
8.1 Product Warranty····························································································· 36
8.2 Disclaimer ······································································································ 36
9 Quick Start Guide ····························································································· 37
9.1 Introduction····································································································· 37
9.2 Robot and Electrical cabinet Installation································································ 37
9.3 Turn on/off the Electrical cabine ·········································································· 38
9.4 Turn on/off the Robot ························································································ 38
10 JAKA Zu Documentation·················································································· 39
10.1 Home Page··································································································· 39
10.2 Manual Operation Page··················································································· 41
10.2.1 Page function instructions·············································································· 41
10.2.2 Robot model······························································································· 42
10.3 Log Information Page······················································································ 43
10.3.1 Robot list area····························································································· 43
10.3.2 Log information area····················································································· 44

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10.4 IO Monitoring································································································· 45
10.5 Programing Control························································································· 45
10.5.1 Programing commands ················································································· 46
10.5.2 Commands instructions················································································· 46
10.5.3 Function buttons area ··················································································· 55
10.5.4 Programing demonstration············································································· 55
10.6 Robot Safety ································································································· 59

JAKA Zu®7 - V1.1 7
Preface
JAKA Zu 7 is at your service. Think what you think and do what you do.
A creative way is used to connect the robot, using the smart mobile terminal plus the APP, so that one
mobile terminal can control several robots. Without the need to master professional programming language,
the user only needs to manually guide the robot to complete the programming, which greatly improves
production efficiency.
JAKAZu 7 is an intelligent, light weight, 6-DOF, modularized collaborative robot with a payload of 7kg, and
it is one of the JAKA Zu Modularized Collaborative Robots Series.
What Do the Boxes Contain
When you purchase a whole package of JAKA Zu 7, the items you will receive are shown in the table
below. (Router, tablet PC, network cables are not included)
Item
Amount
JAKA Zu 7 Robot
1
Electrical cabinet
1
Emergency Stop Button Box
1
Power Supply Cable
1
JAKA Certificate of Quality
1
JAKA Zu 7 User Manual
1
Warranty Card
1

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How to Read This Manual
This manual contains two parts: instructions for installation and programming.
Installation: The mechanical and electrical installation of the robot.
Programming: Robot programming.
This manual will be a big help in both installation and operation to the users who have a basic level of
mechanical and electrical training.

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1 Safety
1.1 Introduction
This chapter contains the safety rules and specifications which should be followed when operating the
robot or robot system. Users should carefully read the safety-related content of this manual and strictly observe
them. Operators should be fully aware of the complexity and hazards of robot system and should pay special
attention to the warning symbols.
1.2 Warning Symbols Descriptions
The hazard level of operating robot system is specified by the following warning symbols. Please strictly
observe them.
DANGER: This indicates an imminently hazardous electrical situation
which, if not avoided, could result in serious injury or death.
DANGER: This indicates an imminently hazardous situation which, if not
avoided, could result in serious injury or death.
WARNING: This indicates a potentially hazardous electrical situation
which, if not avoided, could result in injury or major damage to the equipment.
WARNING: This indicates a potentially hazardous situation which, if not
avoided, could result in injury or major damage to the equipment.
WARNING: This indicates a potentially hazardous hot surface which, if
touched, could result in injury.
CAUTION: This indicates a situation which, if not avoided, could result in
damage to the equipment.

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1.3 Safety Precautions
This section is mainly for the protection of operators and related matters that need to be paid attention to
during the first installation. Users need to carefully read the safety warnings in this manual. We describe
various situations as much as possible although the description cannot be exhaustive.
1. Make sure to install the robot and all electrical equipment according to
the instructions and warnings in this manual.
2. The power cut-off switch should has a mounting height of 0.6m to 1.9m
to ensure that the power can be cut off in a timely and convenient manner in
case of emergency.
3. Before using the robot for the first time, the robot's protective system
and the integrity of the equipment and system, as well as the safety of the
operation should be checked to ensure that there is no damage.
4. A qualified person for robot operation is required to check each safety
function and ensure that the parameters and procedures are correct before the
robot can be started.
5 . The power plug for the robot must have a grounding jack that is reliably
grounded.
1. Professional commissioning personnel are required to install and debug
the robot according to the specifications.
2. The setting and modification of the safety parameters must be carried
out by a licensed person. Unauthorized personnel must not change the
parameters.
3. Do not switch the power supply system frequently. The JAKA Zu 7 has
a brake in each joint to hold position when the power is off.
4. When the robot overload exceeds the default value, the robot will stop
moving to prevent damage to the robot or operator injury. This is because
JAKA Zu 7 has a collision detection function. If the operator uses controllers
not approved by JAKA, the potential risks are to be borne by himself.
1. Make sure the robot and tool are properly and securely bolted in place.
2. Make sure the robot arm has ample space to operate freely.
3. Do not connect any safety equipment to normal I/O. Use safety-related
interfaces only.
4. Make sure to use the correct installation settings (e.g. Robot mounting
angle, weight in TCP, TCP offset, safety configuration). Save and load the
installations file along with the program.
5. Tools and obstacles shall not have sharp edges or pinch points. Make
sure that all people keep their heads and faces outside the reach of the robot.
6. Combining different machines might increase hazards or create new

JAKA Zu®7 - V1.1 11
hazards. Always make an overall risk assessment for the complete installation.
7. Never modify the robot. A modification might create hazards that are
unforeseen by the integrator. JAKA DISCLAIMS ANY LIABILITY IF THE
PRODUCT IS CHANGED OR MODIFIED IN ANY WAY.
8. When transporting the robot, follow the transportation instructions and
handle it carefully to avoid collisions.
1. The robot and electrical cabinet generate heat during operation. Do not
handle or touch the robot while in operation or immediately after operation. To
cool the robot down, power off the robot and wait one hour.
2. Never stick fingers behind the internal cover of the electrical cabinet.
1. When the robot is combined with or working with machines capable of
damaging the robot, it is highly recommended to test all functions and the
robot program separately. It is recommended to test the robot program using
temporary waypoints outside the workspace of other machines.
2. Do not expose the robot to permanent magnetic fields. Very strong
magnetic fields can damage the robot.
1.4 General Warnings and Cautions
1.Do not wear loose clothing or jewellery when working with the robot.
Make sure long hair is tied back when working with the robot.
2. During the operation, even if the robot seems to have stopped, it may
be because the robot is waiting for the start signal and is about to move. Even
in such a state, the robot should be considered to be in motion.
3. During the operation, make sure the power cables of the electrical
cabinet and robot are reliably connected. Do not plug or unplug the power
cables or terminals in the working mode.
4. A warning line should be drawn on the floor to identify the working
range of the robot, so that the operator can understand the working range of
the robot with the end effector (gripper, tool, etc.) mounted.
5. Make sure that safety measures and/or robot safety configuration
parameters have been set up to protect both programmers, operators and
bystanders, as defined in the risk assessment. The lock should be set as
needed so that the non-operator cannot access the robot power supply.
6. In emergency situations such as when a person is caught or
surrounded by the robot, the robot can be forced to move by pushing or pulling
the robot arm. Moving the robot manually without power is for emergency use
only, and may damage the robot.

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1.5 Responsibilities and Risks
Responsibilities
This manual does not cover all applications for designing, installing and operating robots, nor does it cover
all peripheral equipment that may affect the safety of the robot system.
JAKA's integrators are responsible for ensuring compliance with applicable national laws and regulations
to ensure that there are no major hazards in the complete robotic application.
All safety information contained in this manual shall not be considered as a guarantee of JAKA. Even if all
safety instructions are observed, the injury or damage caused by the operator may still occur.
JAKA constantly strives to improve the performance and reliability of our robots. JAKA is not responsible
for any errors or omissions in this manual, and reserves the right of final interpretation of this manual.
Risks
A direct or indirect physical contact relationship exists when there an interaction between the operator and
the robot exists. Operators must have sufficient self-protection awareness when contacting, and integrators
need to carefully consider the use conditions when using the company's robots. The following are possible
dangerous situations:
①Injury caused by the robot dropping during handling;
②Injury caused by the loosening of the robot fixing screw;
③Finger-pinching and collision injury during the operation;
④Injury caused by the unrepaired malfunction robot;
⑤Danger caused by the usage of a sharp end effector or tool connection;
⑥Injury caused by the operation in a toxic or corrosive environment.
1.6 Usages
JAKA Zu 7 is an industrial collaborative robot suitable for use in industrial environments, for example, for
handling tools and fixtures, or for processing or transferring components or products. JAKAZu 7 is only allowed
to be used under specified environmental conditions.
JAKAZu 7 is equipped with special safety-related features, which are purposely designed for collaborative
operation, where the robot operates without fences and/or together with a human. Collaborative operation is
only intended for non-hazardous applications, where the complete application, including tool, work piece,
obstacles and other machines, is without any significant hazards according to the risk assessment of the
specific application.
Any use or application deviating from the intended use is deemed to be impermissible misuse. This
includes, but is not limited to the following:
①Use in potentially explosive environments ;
②Use in medical and life critical applications ;

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③Use before performing a risk assessment ;
④Use where the rated performance levels are insufficient ;
⑤Operation outside the permissible operating parameters.
1.7 Emergency Stop
When an emergency occurs, press the emergency stop button to stop all movement of the robot immediately.
Emergency stop cannot be used as a risk reduction measure, but as a secondary protective device.
1.8 Movement without Drive Power
In the unlikely event of an emergency situation where robot power is either not possible or unwanted, the
robot joint can be forced to move in two ways:
1. Forced manual drive: By pushing or pulling the robot arm, it can force the joint to rotate. The brake of
each joint has a friction clutch. When the joint is subjected to a torque greater than the friction torque of the
friction clutch (about 715 Nm for large joints and 150 Nm for small joints), the joint rotates.
2. Manual brake release: Remove the joint cover by removing the M3 screws (four for big joints and three
for small joints) that fix it. Press the plunger on the small electromagnet (shown below) to release the brake.
Fig 1-1
WARNING:
1. Moving the robot arm manually is intended for urgent emergencies only
and might damage the joints.
2. If the brake is released manually, gravitational pull can cause the robot
arm to fall. Always support the robot arm, tool and work item when releasing
the brake.

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2 Precautions for Transportation and
Handling
Transport the robot in the original packaging. Save the packaging material in a dry place; you may need to
pack down and move the robot later on.
Lift both tubes of the robot arm at the same time when moving it from the packaging to the installation
place. Hold the robot in place until all mounting bolts are securely tightened at the base of the robot.
CAUTIONS:
1. Make sure not to overload your back or other bodyparts when the
equipment is lifted. Use proper lifting equipment. All regional and national
guidelines for lifting shall be followed. JAKA cannot be held responsible for
any damage caused by transportation of the equipment.
2. Make sure to follow the installation instructions when installing the
robot.

JAKA Zu®7 - V1.1 15
3 Mechanical Interface
The robot consists mainly of six joints and two aluminum tube arms (as shown in Fig3-1). The base is used
to install the robot, and the tool end is used to mount the tool. The tool can perform translational and rotational
movements in the robot's working range. The following sections describe the basics to be aware of the
installation of various components in the robot system.
Fig3-1
3.1 Robot Working Range
3.1.1 Robot Dimensions
The photo and dimensions of JAKAZu 7 robot are shown in Fig 3-2 and Fig3-3. Make sure to take into
account the working range of the robot during installation to avoid injury to people or damage to the equipment.
Fig 3-2

JAKA Zu®7 - V1.1 16
Fig3-3
3.1.2 Robot Working Range
The working range of JAKA Zu 7 is shown in Fig 3-4. When choosing the robot installation position, the
cylinder space directly above and below the robot must be considered. Moving the tool close to the cylindrical
volume should be avoided if possible, because it causes the joints to move fast even though the tool is moving
slowly, causing the robot to work inefficiently and making it difficult to conduct a risk assessment.
Fig 3-4
3.2 Installation
3.2.1 General installation steps
1. Determine the working range of the robot
2. Mount the robot on the base
3. Install the required tools at the end of the robot

JAKA Zu®7 - V1.1 17
Fig 3-5
3.2.2 Important safety instructions
DANGER: 1. Make sure the robot is properly and securely bolted in place.
2. The mounting surface must be shockproof and sturdy.
DANGER: 1. Make sure the tool is properly and securely bolted in place.
2. Make sure that the tool is constructed such that it cannot create a
hazardous situation by dropping a part unexpectedly.
DANGER: 1. Make sure that the electrical cabinet and cables do not come
into contact with liquids. Awet electrical cabinet could cause death.
2. The electrical cabinet must not be exposed to dusty or wet
environments that exceed IP20 rating. Pay special attention to environments
with conductive dust.
CAUTIONS: If the robot is bathed in water over an extended time period it
might be damaged. The robot should not be mounted in water or in a wet
environment.
3.2.3 Robot Installation Options
The robot has an attitude and position adaptation function. It can be mounted in various ways, such as

JAKA Zu®7 - V1.1 18
ground, wall, and celling mounting. As shown in Fig 3-6:
Fig 3-6
Using four M8 bolts to mount the robot through the four 9mm through holes on the robot base. It is
recommended to tighten these bolts with a torque of 40 Nm. If you need to adjust the robot installation position
very accurately, you can also drill two φ8 pin holes and fix them with pins. It is also possible to purchase an
accurate base counterpart as an accessory. Mount the robot on a sturdy surface that is strong enough to
withstand at least ten times the full torque of the base joint and at least five times the weight of the robot arm.
Furthermore the surface shall be vibration free. If the robot is mounted on a linear axis or a moving platform
then the acceleration of the moving mounting base shall be very low. A high acceleration might cause the robot
to stop, thinking it bumped into something. Fig. 3-7 shows the robot mounting holes. All measurements are in
mm.
Fig 3-7
3.2.4 End effector Installation
The robot end flange has four M6 tapped holes to
mount the end effector. When screws are installed in
these threaded holes, the screws need to be
tightened with a torque of 15 Nm. If you need to adjust
the tool position very accurately, you can also drill a
φ6 pin hole and fix it with a pin. Fig. 3-8 shows the
drilling position and the screw mounting position. All
measurements are in mm.
Fig 3-8
3
6

JAKA Zu®7 - V1.1 19
4 Electrical Interface
4.1 Introduction
This chapter describes all the electrical interfaces of the robot and electrical cabinet. These interfaces are
divided into five categories, each of which has different purposes and properties:
•Controller I/O
• Ethernet
• Emergency stop button box
• Power connection
• Robot connection
The term "I/O" referring to the digital and analog control signals coming in and out of the interface.
These five types of interfaces are described below, and most types of I/O are provided with examples. The
warnings and cautions in the next section are related to these five sets of interfaces, so be sure to observe
these instructions.
4.2 Warnings and Cautions
Be sure to observe the following warnings and cautions when designing and installing robotic applications.
These warnings and cautions are also apply for service work.
4.3 Controller I/O
This chapter describes the I/O interface in the electrical cabinet, which contains 8 DIs (Digital Input), 8
DOs (Digital Output) and 8 AIs (Analog Input). As shown in Fig 4-1：
Fig 4-1

JAKA Zu®7 - V1.1 20
Hardware interfaces are shown below.
No.
number
Name
Terminals
Functions
1
24V power
supply
voltage
interface
+
Positive terminal of 24V voltage
-
Negative terminal of 24V voltage
2
Ground
terminal
GND
When the drycontact is input, the switch can be collected by connecting this
terminal and DI1 to DI8.
3
8 digital
inputs (DI1 to
DI8)
DI1
1st digital input
DI2
2nd digital input
DI3
3rd digital input
DI4
4th digital input
DI5
5th digital input
DI6
6th digital input
DI7
7th digital input
DI8
8th digital input
4
8 analog
inputs (AI1 to
AI8)
AI1
1st way 0~5V voltage input
AI2
2nd way 0~5V voltage input
AI3
3rd way 0~5V voltage input
AI4
4th way 0~5V voltage input
AI5
1st 4~20mA current input
AI6
2nd 4~20mA current input
AI7
3rd 4~20mA current input
AI8
4th 4~20mA current input
5
Output test
point
OUT
Test output point, can output 5V level, usedfor test purposes of AI1 ~AI8.
6
8 digital
outputs (DO1
~ DO8)
DO1
The first relay output, R and L represent the 2 contacts of the relay
DO2
The second relay output, R and L represent the 2 contacts of the relay.
DO3
The third relay output, R and L represent the 2 contacts of the relay
DO4
The fourth relay output, R and L represent the 2 contacts of the relay
DO5
The fifth relay output, R and L represent the 2 contacts of the relay
DO6
The sixth relay output, R and L represent the 2 contacts of the relay
DO7
The seventh relay output, R and L represent the 2 contacts of the relay
DO8
The eighth relay output, R and L respectively represent the two contacts of
the relay