ROKAE NB220 Series User manual

NB220 Series
P roduct Manu a l

NB220 Series
Product Manual
Document No.:DOC-00001641
Version: A
© Copyright 2015 ROKAE. All rights reserved.

Do not copy or reprint part or all of this manual without the consent of ROKAE.
ROKAE has proofread the contents of this manual. However, the possibility of errors or
inconsistencies cannot be ruled out, and ROKAE shall not be held liable for any errors or
inconsistencies.
This manual is subject to update without prior notice.
We cannot foresee all possible dangers and consequences. Therefore, this manual cannot
warn the user of all possible hazards.
If you find the contents of this manual wrong or in need of improvement or supplement,
please contact us for correction.
This manual is originally written in Simplified Chinese. Other language versions are translated.
© Copyright 2015 ROKAE. All rights reserved.

NB220 Series Product Manual
Content

II NB220 Series Product Manual

NB220 Series Product Manual

1 Manual Overview
NB220 Series Product Manual 1
1Manual Overview
1.1 About this manual
Thank you for purchasing our robot system.
This manual contains the following instructions for correct installation and use of the robot:
⚫Mechanical and electrical installation of the robot
⚫Maintenance and calibration of the robot
Please read this manual and other related manuals carefully before installing and using the
robot system.
After reading, keep the manual properly so that you can read it at any time.
1.2 Target group
This manual is for:
⚫Installation personnel
⚫Maintenance personnel
Please ensure that the above personnel have the necessary knowledge of mechanical and
electrical installation and maintenance, and have received our relevant training.
1.3 How to read the product manual
This manual includes a separate safety chapter that must be read through before proceeding
with installation or maintenance operations.
1.4 Illustrations in this manual
Due to product upgrades or other reasons, some figures in the product manual may differ
from the actual product. However, the operating procedures are correct.
Also, figures of other types of robots may be used to describe some general information.
1.5 Contact
For matters related to maintenance and repair of the robot, please contact our after-sales
department or the local reseller.
Service hotline: [phone].
Get the following information ready when contacting us:
⚫Controller model/serial number
⚫Robot model/serial number
⚫Software name/version
⚫Problems with the system

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NB220 Series Product Manual 3
2Safety
2.1 Introduction
This section describes the safety principles and processes that need to be noted when using
the robot.
The contents related to the design and installation of the external safety protection device of
the robot are not covered within this section. Please contact your system integrator to obtain
such information.
2.1.1 Safety responsibility description
ROKAE is dedicated to but not liable for providing reliable safety information. Even if all
operations are carried out according to the safe operation instructions, we cannot guarantee
that our industrial robots will not cause personal and property losses.
In addition to the safety section, please also note that there are other safety reminders in the
necessary parts of the document.
2.1.2 Using the robot in compliance
The industrial robots should be used in accordance with local laws and regulations, and must
not be used for any purpose that violates such laws and regulations.
Using the robot in compliance also means observing the instructions in product manuals of
various individual components, including the operation, installation and maintenance
instructions for them.
The following uses that violate the rules shall be prohibited:
⚫Transporting people and animals
⚫Using in environments with explosion hazard
⚫Using in flammable environments
⚫Using outside the permissible range
⚫Using downhole
2.2 Safety terms
2.2.1 Safety symbols
2.2.1.1 About safety symbols
There may be different degrees of danger when operating the robot in accordance with this
manual, so there will be a special safety symbol in the vicinity of dangerous operation
instructions to remind the user to be careful. The contents include:
⚫An icon that indicates safety level and the corresponding name, such as warning,
danger, tips, etc.;
⚫A brief description given to illustrate the possible consequences if the operator
does not eliminate the danger;
⚫Operating instructions on how to eliminate dangers.
2.2.1.2 Safety levels

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4 NB220 Series Product Manual
Icon
Name
Description
Danger
For those coming with this sign, failure of following the rules
in operation may cause serious or even fatal injury to
personnel, and will/may cause serious damage to the robot.
Operations related to such hazards include contacting high-
voltage devices in the control cabinet, entering the working
area when the robot is running, etc.
Warning
For those coming with this sign, failure of following the rules
in operation may cause serious and even fatal personal injury,
and will cause a great damage to the robot.
Alert
For those coming with this sign, failure of following the rules
in operation may cause personal injury, and may cause
damage to the robot.
Tips
This icon indicates important information or prerequisites.
2.2.2 Hazard description
2.2.2.1 Hazards
Icon
Name
Description
Squeezing
There may be an injury to the operators and maintenance
personnel who enter into the motion range of the robot during
debugging, repair, overhaul and tool installation.
Hand
pinching
There may be a risk of hand pinching when the maintenance
personnel approach the belt drive parts or other moving parts
during maintenance.
Strike
There may be a serious injury to the operators and
maintenance personnel who enter into the motion range of
the robot during debugging, repair, overhaul and tool
installation.
Friction
There may be an injury to the operators and maintenance
personnel who enter into the motion range of the robot during
debugging, repair, overhaul and tool installation.
Parts
flying out
There may be a serious injury to the operators and
maintenance personnel who enter into the motion range of
the robot during debugging, repair, overhaul and tool
installation when tools or workpieces fly out due to loose
clamping.
Fire
There may be a serious injury due to fire that might occur in
case of electrical short circuit or the wire or device on fire.
Hot
surface
During the maintenance and repair of the equipment, a burn
may be caused if the maintenance personnel touch the
robot's hot surface.
Electric
shock
The current operation may cause an electric shock with a
serious or even fatal injury.

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NB220 Series Product Manual 5
Icon
Name
Description
ESD
The components involved in the current operation are
sensitive to static electricity. Failure to operate according to
specifications may cause component damage.
Warning
Any robot in motion is a potentially fatal machine!
When the robot is running, it may execute undesirable or even unreasonable motions. In
addition, the robot carries huge energy when it is running. It will cause serious
damage/injury to the personnel and equipment in its working area in case of collision.
2.2.2.2 Danger elimination
Operation
Reference information
1
Before running the robot, make sure that all
safety protection devices have been
properly configured and installed.
Safety protection devices include the
emergency stop button, safety gate,
safety grating, etc.
2
In the process of robot programming, the
personnel who enter the robot working
area must hold the Teach Pendant.
Personnel outside the working area
must avoid using the Teach Pendant
to operate the robot without
observing the personnel inside the
working area.
3
Before starting the robot program, make
sure that there are not any person in the
robot working area.
4
When programming the robot's motion,
make sure to identify potential collision
risks before the first commissioning.
2.2.3 Safety features
2.2.3.1 Description
This robot system is equipped with a special safety controller for handling safety-related
signals, and provides external safety symbol interfaces such as the safety gate and
emergency stop button.
Signals processed or outputted by the safety controller include:
⚫Emergency stop button signal
⚫Safety gate signal
⚫Enabling switch signal
⚫Mode selection signal
⚫Emergency stop status signal
2.2.3.2 Applicable safety standards
The robot system is designed in accordance with the following relevant standards:
Standard
Description
2006/42/EC
Machinery directive
2014/30/EU
Electromagnetic compatibility directive
EN ISO 12100:2010
Safety of machinery - General principles for design - Risk
assessment and risk reduction

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6 NB220 Series Product Manual
Standard
Description
EN ISO 10218-1:2011
Industrial robots –Safety requirements Part 1: Robots
EN ISO 13849-1:2015
Safety of machinery - Safety-related parts of control systems
–Part 1: General principles for design
IEC 60204-1:2016
Safety of machinery - Electrical equipment of machines - 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 62061:2010
Safety of machinery - Functional safety of safety-related
electrical/electronic/programmable electronic control
systems
IEC 61000-6-2:2016
Electromagnetic compatibility - Generic standards - Immunity
standard for industrial environments
IEC 61000-6-4:2011
Electromagnetic compatibility - Generic standards - Emission
standard for industrial environments
2.2.4 Motion enabling and safe stop
2.2.4.1 Motion enabling
The motion control function of the robot control system should be enabled by the safety
controller, which, when determining the safety level of the current environment through
internal logic, controls on/off of drive STO (Safe Torque Off) via safety output signal. Manual
operation of the robot by the user and automatic running of the program are not allowed by
the control system before the safety controller determines that it is safe at the moment.
2.2.4.2 Safe stop
There are three ways to stop the robot, i.e. STOP 0, STOP 1 and STOP 2.
Safe stop refers to stop triggered by the safety controller, which only involves STOP 0 and
STOP 1, while STOP 2 can only be triggered by the control system.
⚫STOP 0
As the stop method of the highest safety level, STOP 0 cuts off the power source of the motors
and engages the band-type brakes of individual joints immediately. During the stopping
process, however, the robot is uncontrolled and may deviate from the programmed path after
it is stopped.
Safe stop in manual mode is STOP 0. Safe stop caused by operating mode switchover in
automatic mode is also STOP 0.
⚫STOP 1
Once STOP 1 is triggered, the control system immediately executes the deceleration process
along the programmed path. Thereafter, whether or not the robot comes to a complete stop,
the safety controller will always cut off the power source of the motors and engage the band-
type brakes of all joints. Since the stop is controlled, in most cases, the robot will finally stop
on the programmed path. Therefore, This emergency stop method provides the best
protection for nearby equipment.
Both safe stops arising from the opening of safety gate/safety grating in automatic mode and
pressing of the emergency stop button in automatic mode are STOP 1.

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NB220 Series Product Manual 7
⚫STOP 2
Once STOP 2 is triggered, the control system immediately executes deceleration along the
programmed path until the robot stops completely. The power source of the motors is
maintained and the band-type brakes are still disengaged, while the robot stays in the current
position.
2.2.4.3 Emergency stop
As one of the safe stops, emergency stop is the function of the highest priority in the robot
system. Pressing the emergency stop button triggers the emergency stop function. All other
robot control functions will stop, the robot will stop movement, the power source of the motors
of all joints will be cut off, and the control system will switch to the emergency stop state.
Such state will be maintained until reset.
The emergency stop state means that, except the manual band-type brake release circuit, all
other power supplies to the robot arm body will be cut off and the reset operation must be
executed to restore the system to its normal condition.
Tips
2.2.5 Safety devices
2.2.5.1 Emergency stop button
Most emergency stop buttons are in red. The most common shape is a mushroom. In general,
a yellow substrate, protective casing or warning sign is also attached to the emergency stop
button. The emergency stop button is mechanically locked when it is pressed. This is the
safety lock mechanism for the button. The device must be reset through manual release. Most
emergency stop buttons are released by rotation and the direction of rotation is indicated on
the button surface. Some buttons also support releasing by upward pulling.
2.2.5.2 Enabling switch
The enabling device is a special switch with two pressing modes and three positions, which
is also called three-position enabling switch (hereinafter referred to as "enabling switch"), and
is used to control on/off of the power supply of the robot in manual mode, thus realizing
motion enabling of the robot.
The enabling switch is installed on the back of the Teach Pendant, as shown in Fig. 1. The
motor power supply is switched on only when the enabling switch is pressed and kept in the
middle position, so that the robot is allowed to move, and you can perform Jog or run
programs. Either releasing or pressing all the way down will cut off the motor power supply.

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Fig. 1 Enabling switch
No.
Description
1
Position 1
2
Position 2
3
Position 3
4
Lightly press
5
Heavily press
6
Release
Warning
It is strictly prohibited to use any external devices to keep the enabling switch locked or
stopped in the middle position!
Tips
Under any circumstances, ensure that the enabling switch can work properly.
During programming and debugging, the enabling switch should be released as soon as
possible when robot motion is not required.
2.3 Safety precautions
2.3.1 Overview
2.3.1.1 About the robot
Regardless of the motion velocity, industrial robots pose great potential hazard. A quick and
dangerous motion command may be performed following a pause or waiting during program
running. Even if you know the motion trajectory and mode of the current robot, the motion
trajectory of the robot in auto mode may still be changed by external signals without warning.
Therefore, one must observe the safety specifications when entering the working range of the
robot.
2.3.1.2 About this section
This section will describe some basic safety specifications to the end users of the robot.

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NB220 Series Product Manual 9
However, it cannot cover each specific circumstance due to limited space.
2.3.2 About the user's own safety
2.3.2.1 Basic principles
To ensure safety when using the robot, the following principles must be observed strictly:
⚫The personnel are only allowed to operate the robot in manual mode when they
are within the safety zone of the robot.
⚫You should hold the Teach Pendant in your hands when entering the safety zone
of the robot to ensure that the robot is under your control.
⚫Pay attention to the active tools installed on the robot, such as the electric drill
and electric saw. Make sure that all these tools have stopped running before you approach
the robot.
⚫Pay attention to the workpiece surface or the robot arm body. The motor and
casing temperature of the robot may become very high after prolonged work.
⚫Pay attention to the gripper of the robot and the objects gripped. If the gripper is
opened, the workpiece may fall off and cause personal injury or equipment damage.
Moreover, the gripper used on the robot may be very powerful and may cause injury if it is
not used according to the specification;
⚫Pay attention to the electrical components in the robot control cabinet. Even if
the power supply has been switched off, the remaining power in the component is still
very dangerous.
2.3.3 Safety precautions for operating the Teach Pendant
2.3.3.1 Safe storage of the Teach Pendant
The Teach Pendant no longer used should be removed from the control cabinet and properly
stored in a place that is far away from the robot workstation or control cabinet, so as to prevent
the operator from mistakenly believing that this Teach Pendant is still connected to the control
cabinet and attempting to use it to stop the robot in case of danger.
2.3.3.2 Teach Pendant cable
The Teach Pendant and control cabinet are connected through a Teach Pendant cable. Please
comply with the following requirements when using the Teach Pendant in order to avoid
personal injury or equipment damage:
⚫Make sure that the personnel do not stumble over the Teach Pendant cable so
as to avoid falling of the Teach Pendant or personnel.
⚫Do not squeeze the Teach Pendant cable, otherwise, its internal cores may be
damaged.
⚫Do not put the Teach Pendant cable on the edge of sharp objects, otherwise, the
cable sheath may be damaged.
⚫Make sure that the bending radius of the Teach Pendant cable is greater than
100mm, otherwise, the cable may be damaged.
2.3.3.3 Permission of using the Teach Pendant
The mode selection switch of a standard Teach Pendant is equipped with a key, i.e. switchover
between manual/auto modes is only possible using the key. Please keep the key properly and

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carefully consider the user permission of the key. Generally, only those personnel who have
completed safety training and basic operation training can have the permission to use the key.
Warning
The key to the mode selection switch on the Teach Pendant is designed for all Teach
Pendants of the same model according to standard.
Ensure that all keys are kept by qualified personnel to prevent misuse.
The user permissions for operating the Teach Pendant interface should also be distinguished
to ensure that the debugging personnel and maintenance personnel can use the Teach
Pendant correctly and reasonably according to their work.
Three user levels are built into the control system, namely operator, admin and god. The
operation permissions rank from low to high. A password must be entered when a user with
lower permission level wants to switch to a higher one; but not vice versa. A user of higher
level can modify the password of a same- or lower-level user. You cannot modify the password
of an operator. For the operation contents of different permission levels, refer to the
corresponding control system operation manual.
2.3.3.4 No Teach Pendant mode
When the No Teach Pendant mode is selected for the control system, special attention must
be paid to safety during debugging and programming. An emergency stop button device must
be installed or placed within the reach of the operator and the signal of the emergency stop
button must be routed into the safe IO interface of the robot system so that the person can
protect the safety of himself/herself and the equipment by pressing the emergency stop
button promptly in case of emergencies.
2.3.4 Safety precautions for using the control cabinet
2.3.4.1 Make sure that there is no conductive foreign objects in the control cabinet
After operations such as repair and component replacement on the control cabinet, make sure
to check if there is any conductive foreign object in the cabinet. Such objects may cause short
circuit in the control cabinet during use of the robot, thus resulting in other dangers.
2.3.4.2 Do not supply power to the control cabinet when the cabinet door is open
⚫Make sure that the cabinet door has been closed before switching on the robot
control cabinet.
⚫Not all electrical devices or nodes in the control cabinet are protected. Therefore,
do not use the control cabinet when the cabinet door is open to avoid fatal danger to the
operator or equipment!
⚫The control cabinet cannot reach the claimed protection level when the cabinet
door is open.
⚫When the cabinet door is open, components in the cabinet are more prone to
electromagnetic interference and may generate excessive radiation to the outside, thus
directly affecting the use of the robot system.
2.3.4.3 Do not use the control cabinet for other purposes
The control cabinet is only used to control motion of the robot arm body. Using it for any other
purposes, such as standing on the cabinet body, working on the control cabinet and using the

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NB220 Series Product Manual 11
cabinet body as a ladder, is prohibited.
2.3.5 Emergency stop button test
The emergency stop button is the only means to trigger the emergency stop as well as the
most important device to protect the safety of operators and equipment in case of emergency.
Therefore, when the robot is put into use for the first time and when the robot is started for
the first time after an overhaul, you must first test the emergency stop button, including testing
the external emergency stop button that the integrator has connected into the robot system,
so as to confirm that pressing the emergency stop button can force the equipment to enter
the emergency stop state and executing the reset operation can exit the emergency stop state.
Only after confirming the normal operation of the emergency stop button can you conduct
configuration or programming on the robot.
2.3.6 Resetting the emergency stop
2.3.6.1 Description
When the system is in the emergency stop state, reset it to return to its normal state. The reset
process is simple but very important. It ensures that the robot system will not be put into
production and operation in a dangerous state.
2.3.6.2 Resetting the emergency stop button
All button-shaped emergency stop devices are equipped with a safety lock mechanism, which
must be released manually after being pressed to reset the emergency stop. Most emergency
stop buttons are released by rotation and the direction of rotation is indicated on the button
surface. Some buttons also support releasing by upward pulling.
2.3.6.3 Operating procedures of resetting the emergency stop
NO.
Operation
1
Confirm that the dangerous conditions causing emergency stop have been
handled properly and the danger is removed.
2
Reset the safety device causing emergency stop.
3
Press the reset button on the control cabinet or click the reset button on the Teach
Pendant/PC interface to recover the system from the emergency stop state. In
auto mode, you can also use the system input signal to reset the system
emergency stop state.
Caution! This operation depends on the control cabinet model. For specific
operations, refer to the corresponding control cabinet product manual and control
system operation manual.
2.3.7 Band-type brake test
When the system enters the emergency stop state, the power source of the motors will be cut
off and the band-type brakes of all joints will engage. Therefore, the normal operation of the
band-type brakes helps ensure the safety of the operator and reduces risks when the robot
enters the emergency stop state.
During daily use of the robot, normal wear will occur to the band-type brakes of individual
joints. It is very necessary to carry out band-type brake tests to ensure its functioning.
The testing method is as follows:
NO.
Operation

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1
In manual mode, run each axis to its maximum load position.
2
Press the enabling switch and keep it in the middle position.
Then the motor power supply is switched on and the band-type brakes are
disengaged.
3
Release the enabling switch to engage the band-type brakes.
Observe if the robot arm body keeps its previous position.
You can observe the angle value of each axis through the Teach Pendant to
confirm that the position of each joint remains unchanged.
4
Test each axis one by one.
If the position of each axis remains unchanged, it is believed that the band-type
brake function works well.
2.3.8 Manual release of the band-type brake
When the robot is in the emergency stop state, all other power supplies to the robot arm body
are cut off except the manual band-type brake release circuit. In case of emergency, you can
move the robot arm body by manually releasing the band-type brake.
A band-type bake release button is installed on the standard control cabinet. When this
function is not used, keep the protective cover of this button in place so as to prevent this
function from being triggered mistakenly.
The band-type brake release button is also installed on some models of robot arm bodies. The
method for triggering this function is different based on the models. Please carefully check
the product manual of the corresponding arm body.
Danger
Before manually releasing the band-type brake, make sure that the trapped person and
operator will not be injured during the process of moving the arm body!
Warning
When moving the robot arm body by manually releasing the band-type brake, please
note:
For small-load models, you can manually move each axis of the arm body. For medium-
and large-load models, a traveling crane, a hoist or other equipment should be used to
help move each axis of the arm body.
2.3.9 Safety precautions in manual mode
2.3.9.1 About manual mode
In manual mode, the motion of the robot is under manual control. Only when the enabling
switch is in the middle position can you perform Jog or run programs on the robot.
The manual mode is used to write and debug robot programs and engage in commissioning
of the workstation.
2.3.9.2 Speed limitation in manual mode
The motion velocity of the robot end is limited to less than 250mm/s in manual mode. This
means that the maximum motion velocity of the robot end will not exceed 250mm/s whether
you perform Jog or run programs on the robot, regardless of the set velocity in the program.