JAKA Zu pro Series Instructions for use

JAKA ROBOTICS
User Manual-Hardware
This manual also applies to Zu pro series
JAKA Zu 5

JAKA ROBOTICS
User Manual
Robot Se rial Number:
Cabinet Serial Number :
JAKA Zu 5

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CAUTION:
The information contained in this manual is the exclusive property of Shanghai JAKA Robotics Co., Ltd.
(hereinafter referred to as JAKA), and shall not be reproduced or transmitted without JAKA’s prior written
approval.
Regular revision and improvement of the JAKA user manual may be made without further 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.
JAKA robot owners and operators must be responsible for their own safety. JAKA is not responsible for the
safety of using robots.
JAKA reminds users that they must use safety equipment and comply saftey protocols when using and
maintaining JAKA robots.
Programmers and other users of JAKA robots must be familiar with JAKA robot programming and system
integration.
IP class of Zu series is IP54, IP class of Zu pro series is IP65.
How to Read This Manual
This manual mainly contains the safety notice, mechanical and electrical interfaces, installation and
Maintenance. For software usage, please refer to the software part.
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.More Information
If you want to know more information about this product,
please scan the QR code to the right, or visit
our website at www.jaka.com.
The definition of cooperative robots follows international ISO standards and relevant provisions of national
standards to protect the safety of operators. We do not recommend to apply the robot directly to the situation
where the object of operation is human body. However, when robot applicants or application developers do
need to involve robotic objects as human beings, they need to fully evaluate the safety of personnel and
configure a safe and reliable, fully tested and certified security protection system for the robot body to protect
the safety of personnel.
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目录
HOW TO READ THIS MANUAL............................................................................................................................... 1
PREFACE......................................................................................................................................................................4
WHAT DO THE BOXES CONTAIN.......................................................................................................................... 4
1 SA FET Y ..................................................................................................................................................................5
1.1 INTRODUCTION..................................................................................................................................................... 5
1.2 WARNING SYMBOLS DESCRIPTIONS...................................................................................................................5
1.3 SAFETY PRECAUTIONS........................................................................................................................................ 5
1.4 GENERAL WARNINGS AND CAUTIONS.................................................................................................................7
1.5 LIABILITIES AND RISKS.........................................................................................................................................7
1.6 USAGE..................................................................................................................................................................8
1.7 EMERGENCY STOP.............................................................................................................................................. 9
1.8 MOVEMENT WITHOUT DRIVE POWER................................................................................................................. 9
1.9 PRECAUTIONS FOR TRANSPORTATION AND HANDLING......................................................................................9
2 WELCOME FROM JAKA ZU ROBOT............................................................................................................... 11
2.1 OVERVIEW OF ROBOT CONFIGURATIONS.......................................................................................................... 11
2.2 OPERATION TERMINAL.......................................................................................................................................11
2.3 ROBOT ARM....................................................................................................................................................... 12
2.3.1 Robot End.....................................................................................................................................................12
2.3.2 Flange Buttons and interfaces..................................................................................................................... 13
2.4 ELECTRICAL CABINET AND CONTROL STICK....................................................................................................14
3 MECHANICAL SPECIFICATION.........................................................................................................................16
3.1 ROBOT WORKING RANGE................................................................................................................................. 17
3.1.1 Robot Dimensions........................................................................................................................................17
3.1.2 Robot Working Range.................................................................................................................................. 17
3.2 INSTALLATION..................................................................................................................................................... 18
3.2.1 General installation steps............................................................................................................................ 18
3.2.2 Important safety instructions...................................................................................................................... 19
3.2.3 Robot Body Installation................................................................................................................................19
3.2.4 End effector Installation...............................................................................................................................20
4 ELECTRICAL INTERFACE.................................................................................................................................. 21
4.1 INTRODUCTION...................................................................................................................................................21
4.2 WARNINGS AND CAUTIONS............................................................................................................................... 21
4.3 FRONT PANEL OF THE ELECTRICAL CABINET.................................................................................................... 22
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4.3.1 All digital I/O common specifications.......................................................................................................... 25
4.3.2 Digital Input (DI)...........................................................................................................................................28
4.3.3 Digital Output(DO)....................................................................................................................................... 29
4.3.4 Analog Input&Output(AI&AO).....................................................................................................................30
4.3.5 High Speed Interface....................................................................................................................................31
4.3.6 Remote ON/OFF...........................................................................................................................................31
4.3.7 Safety I/O..................................................................................................................................................... 31
4.4 BOTTOM PANEL OF THE ELECTRICAL CABINET..................................................................................................31
4.4.1 Power Connection........................................................................................................................................32
4.4.2 Robot Connection........................................................................................................................................ 32
4.5 TOOL INPUT AND OUTPUT................................................................................................................................. 33
4.5.1TIO function description............................................................................................................................... 33
4.6 TECHNICAL SPECIFICATIONS............................................................................................................................. 35
5 MAINTENANCE AND REPAIR............................................................................................................................37
5.1 SAFETY INSTRUCTIONS..................................................................................................................................... 37
5.3.1 Filter cleaning and replacement.................................................................................................................. 40
5.3.2 Part preservation......................................................................................................................................... 40
6 APPLIED STANDARDS AND CERTIFICATES................................................................................................ 43
6.1 COLLABORATIVE ROBOT CERTIFICATION.......................................................................................................... 43
6.2 INDUSTRIAL ROBOT CERTIFICATION..................................................................................................................44
6.3 FUNCTIONAL SAFETY CERTIFICATION............................................................................................................... 45
6.4 CE EMC CERTIFICATES....................................................................................................................................48
6.5 CE MD CERTIFICATES.......................................................................................................................................49
6.6 ROHS CERTIFICATES.........................................................................................................................................50
7 WARRANTY............................................................................................................................................................ 51
7.1 PRODUCT WARRANTY....................................................................................................................................... 51
7.2 DISCLAIMER........................................................................................................................................................52
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Preface
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.
What Do the Boxes Contain
Item Amount
Robot 1
Electrical cabinet 1
Key to cabinet 1
Power Supply Cable 1
JAKA Certificate of Quality 1
User Manual 1
Warranty Card 1
JAKAZu 5 is at your service. Think what you think and do what you do.
JAKAZu 5 is an intelligent, light weight, 6-DOF, modularized collaborative robot with a payload of 5kg
, and belongs to the JAKA Zu Modularized Collaborative Robots Series
When you purchase a whole package of JAKAZu 5 , the items you will receive are shown in
the table below.
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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 situatio
n
which, if not avoided, could result in serious injury or death.
DANGER:
This indicates an imminently hazardous situation which, if no
t
avoided, could result in serious injury or death
WARNING:
This indicates a potentially hazardous hot surface which, i
f
touched, could result in injury.
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.
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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.
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 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.
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 put hand behind the internal cover of the electrical
cabinet.
3.Do not switch the power supply system frequently. The
JAKAZu5 has a brake in each joint to hold position
when the power is off.
4.When the external force exceeds the safety value, the robot will
stop moving to prevent damage to the robot or operator injury. This is
because JAKAZu5 has a collision detection function. If
the operator uses controllers not approved by JAKA, the potential
risks are to be borne by himself.
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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 way points 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。
1.5Liabilities and Risks
Liabilities
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.
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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 Usage
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 ;
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.
JAKAZu 5 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.
JAKAZu 5 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 5 is only allowed to be used under specified environmental conditions.
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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, the joint rotates.
2. Manual brake release: Remove the joint cover by removing the 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
Warnings:
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.
1.9 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 body parts 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.
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2 Welcome from JAKA Zu Robot
2.1 Overview of robot configurations
Fig 2-1 Overview of robot configurations
Router and network cables：The Ethernet port of the cabinet is connected to the router, so as the
operation terminal. It is recommend that a dedicated router is used to ensure reliable connection.
2.2 Operation Terminal
JAKAZu 5
Before reading this chapter, please ensure that chapter 1 Safety has been read and fully understood.
In this chapter the basics of JAKA Zu Robots would be introduced , for future hardware
specifications and software usages please refer to other chapters.
During using of JAKA Zu robots，if quick help is needed, feel to free to call our hotline
:([phone].
As shown in Fig 2-1, JAKA Zu robots uses wireless connection, and the followings are needed：
Operation Terminal：Device used to program and set robot.
Robot Arm：The core moving part of robot to achieve designated movements. And at the end of the arm,a
ring indicator, buttons used to drag and tech, TIO interface are located.
Electrical Cabinet ontrol Stick：The cabinet contains the robot controller and many different kinds
of electrical interface，And also equipped with a control stick.
JAKA Zu APP is provided by JAKA on Android system, and the required configurations are as
follows:

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Terminal Type Tablet PC
OS Android 8.0 or above
CPU Kirin695or Snapdragon 660
ROM 32GB
RAM 4GB
Screen Size 8.0 inch
Network WIFI
Table2-1 Operation Terminal Required Hardware Configurations
The operation terminal can be requested during purchasing or provided by user themselves.
2.3 Robot Arm
The robot arm is shown as Fig 2-1, and is composed of six rotation joints with two linkages. And at the end
of the arm,a ring indicator, buttons used to drag and tech, TIO interface are located.
Fig 2-1 Robot Arm
2.3.1 Robot End
At the end of the robot, an indicator and a pause button is located.
The indicator and the pause button is located as Fig 2-2 and the meanings of different color are listed in
table 2-2. When the robot is running program, press the pause button could pause and resume the program.
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Fig 2-2 Ring Indicator and Pause Button
Color Robot Status
Blue Power on
Green Enabled
Red Fault
Yellow Drag Mode
Flashing
Yellow Pause Mode
Table 2-2 Indicator Meanings
Warnings:
The risks related to using of pause button should be evaluated carefully, the contact of robot and personnel
could cause server injury of personnel or damage of equipment.
2.3.2 Flange Buttons and interfaces
On the side of flange located two buttons and TIO interface.The buttons are FREE button and POINT
button Respectively, shown as below:
The detailed description of TIO is in chapter 4.
When the free button is pressed, the robot would enter free-drive mode.
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The point button could be used with the robot APP, and when this button is pressed the robot position
would be recorded in the APP.
Warnings:
The risks related to using of pause button should be evaluated carefully, the play load、TCP setting should
be set properly, otherwise the contact of robot and personnel could cause server injury of personnel or
damage of equipment.
2.4 Electrical Cabinet and Control Stick
Along with the cabinet a stick is provided, and when the programming job is finished , the stick could be
sued to control the robot.
Commands can be sent to the robot using buttons on the stick, and are described as follows:
table 2-3 Stick Function Description
ON/OFF
ON：Press the power button for 1 second and release it, The buzzer will
ring and the electric control cabinet will start up.
OFF：Press and hold the power button for more than 3s, the handle
buzzers 6~7 times, and the electric control cabinet is turned off.
Power
/Enable
Turn on robot：When robot turned off, short press the button to turn on the
robot.
Turn off robot：When robot turned on, short press the button to turn off the
robot.
Enable robot：When robot turned on, short press the lock button a nd
enable button.
The cabinet of JAKA Zu Robots contains several kinds of interfaces which are described in chapter 4.
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Disable robot：When robot enabled, short press the lock button + enable
button
Start/
Stop
Run program: press the terminate button to start the default loaded
program. After robot moves to the initial position of the program, execute the
default program .
Terminate program: When program operating, short press the button to
terminate the program.
Home
Reset：After robot enabled, when no program is operating, press
continuously to control the robot to run to the set default position. When robot
moves to the default position, press continuously and the lock indicator light is
blue.
Pause/
Resume
Pause: When the robot moving automatically, press to pause the program.
Recovery: When robot paused, press to recover the program running.
Lock/Fn
Locking handle: Press and hold the lock button for 3 seconds, and the
lock indicator light will be orange.
Unlock handle: Press and hold the lock button for 3 seconds, and the lock
indicator light will go out.
Combination function: Other buttons and lock button can be pressed in
combination.
Lock
indicator
Locked state: When locked, the indicator is orange. Except for the unlock
and on/off button, other buttons are invalid. APP can control the robot.
Unlocked state: When unlocked, the indicator is off and the handle can be
used. The APP interface is gray and you can not control the robot.
Emergency
Stop
For emergency stop.
Note: The emergency stop button is only used in emergency situations and
cannot be used as a general power-off device.
Note：
After powering on, press any button and the handle will beep at a frequency of 2 times per second.
When using the handle to operate the robot, please ensure that the robot under operating is within the line
of sight, and follow the relevant safety rules to prevent injury to the people or equipment around the robot.
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3 Mechanical Specification
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.
Fig 3-1
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3.1 Robot Working Range
3.1.1 Robot Dimensions
Fig3-2
Fig3-3
The photo and dimensions of JAKAZu 5 robot and electrical cabinet 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.
3.1.2 Robot Working Range
The working range of JAKAZu 5 is shown in Fig 3-4. When choosing the robot installation
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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.
Fig3-4
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.
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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. A wet 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 Body Installation
The robot has an attitude and position adaptation function. It can be mounted in various ways, such as
ground, wall, and celling mounting. As shown in Fig 3-5:
Fig 3-5
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
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