rozum robotics PULSE 75 Assembly instructions

ROZUM ROBOTICS PULSE robotic arm
Rev. 6, in effect from Q2 2019
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TABLE OF CONTENTS
INTRODUCTION......................................................................................................................... 4
WARNING SIGNS AND THEIR MEANINGS......................................................................... 4
1PRODUCT OVERVIEW..................................................................................................... 5
1.1 Basic features and components..................................................................................... 5
1.2 Use restrictions ............................................................................................................... 6
1.3 Supply package............................................................................................................... 7
1.4 Specifications of the robotic arm .................................................................................. 7
1.5 Operating conditions.................................................................................................... 10
1.6 Control box................................................................................................................... 10
1.6.1 The front panel........................................................................................................ 11
1.6.2 The back panel........................................................................................................ 11
1.6.3 Sound signals.......................................................................................................... 12
1.7 Emergency stop button................................................................................................ 12
1.8 Wrist.............................................................................................................................. 14
1.9 Control buttons............................................................................................................. 15
2INSTALLATION................................................................................................................ 15
2.1 General requirements.................................................................................................. 15
2.1.1 Continuous power supply requirement................................................................... 16
2.2 Mechanical integration................................................................................................ 16
2.2.1 Mounting the robotic arm ....................................................................................... 16
2.2.2 Installing the control box........................................................................................ 18
2.3 Electrical integration.................................................................................................... 18
2.3.1 Power connection.................................................................................................... 18
2.3.2 Digital I/O connectors............................................................................................. 18
2.4 Mounting an end effector ............................................................................................ 20
2.5 Integrating the arm into an application..................................................................... 21
3COMMISSIONING............................................................................................................ 23
3.1 Pre-commissioning checks........................................................................................... 23
3.2 Switching the arm......................................................................................................... 24
3.3 Setting up communication with a PULSE arm ......................................................... 24
3.3.1 Static IP................................................................................................................... 25
3.3.2 Dynamic IP ............................................................................................................. 29
3.4 Starting the PULSE DESK.......................................................................................... 29

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3.5 Enabling control via API............................................................................................. 30
3.6 Switching off a PULSE robotic arm........................................................................... 31
ANNEX I. KINEMATICS OF THE PULSE ARM................................................................. 32

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INTRODUCTION
This manual is intended to assist an integrator in installing and commissioning a system
comprising the PULSE robotic arm (hereinafter, a robotic arm or an arm), an end effector (also, a
work tool), a control box, and an emergency stop button. The document contains the following
information about the system:
basic features and components
operating conditions and use restrictions
dimensions and specifications
requirements and instructions on mechanical and electrical integration
pre-commissioning checks and the commissioning procedure
WARNING SIGNS AND THEIR MEANINGS
Below are the warning symbols used throughout the manual and explanations of their meanings.
The sign denotes important information that is not directly related to safety, but that the
user should be aware of.
The sign indicates important safety precautions the user should follow.

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1PRODUCT OVERVIEW
1.1 Basic features and components
The PULSE robotic arm is designed for collaborative operation in industrial and commercial
applications (e.g., pick-and-place, screwing, welding, etc.).
Although the arm is designed to operate safely in close proximity to humans, the
integrator must conduct risk assessments for specific installations to evaluate the
need for additional safety measures (e.g., safeguards).
Apart from the robotic arm, the supply package includes the hardware and software components
listed in Table 1-1.
Table 1-1:Hardware and software components supplied with the PULSE arm
Component
Intended use
For details,
refer to
Hardware
Control box
To control operation of the PULSE robotic arm
Section 1.6
Emergency
stop button
To ensure Category 1 stop of the robotic arm in an emergency
Section 1.7
Software
PULSE DESK
The software is pre-installed on the PC module integrated into
the control box. It allows for programming the arm to move
along a desired trajectory and perform different kinds of
operations with a work tool.
User Manual
The PULSE robotic arm boasts modular design comprising elements as below (Figure 1-1):
aluminum alloy tubes (1)
Rozum Robotics self-designed servo motors (2)
elbow fittings (3)
Figure 1-1:Structural elements of the PULSE robotic arm

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The elements form six interlinked axes (see Figure 1-2). In addition, the arm includes the
following structural segments:
an end effector mounting flange (a wrist)
an arm base
a transition plate
Figure 1-2:Structural segments of the PULSE robotic arm
1.2 Use restrictions
Make sure to observe the following use restrictions for the PULSE robotic arm:
Failure to observe the restrictions shall constitute a misuse, making our warranty
void.
Never install or operate the PULSE robotic arm in an explosive or flammable environment.
The atmosphere at the operating location of the robotic arm should not contain corrosive
gases or liquids, salt, radioactive substances, oil mist, dust or metal powders.
Always conduct a risk assessment of the operating environment before installing and
operating the PULSE robotic arm.
Avoid using the PULSE robotic arm outside the operating conditions (see Section 1.5).
1
Transition plate
2
Arm base
3
Axis 1
4
Axis 2
5
Axis 3
6
Axis 4
7
Axis 5
8
Axis 6
9
Wrist (end effector
mounting flange)

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1.3 Supply package
The supply package of the PULSE robotic arm contains the following components:
a robotic arm assembled with a transition plate and a wrist
a control box
an emergency stop button pre-assembled with a connection cable
a 220 V power cable
a hybrid cable to connect the robotic arm and the control box
1.4 Specifications of the robotic arm
The PULSE robotic arm has the specifications as listed in Table 1-2.
Table 1-2:Specifications of the PULSE robotic arm
Specification
PULSE 75
PULSE 90
Weight1)
12.6 kg
17.4 kg
Payload1)
4 kg
3 kg
Degrees of freedom1)
6
6
Reach1)
750 mm
900 mm
Repeatability
+/-0.1 mm
+/-0.1 mm
Non-stop lifetime cycle
20,000+ hours
20,000+ hours
Protection class
IP40
IP40
Noise level
less than 60 dB
less than 60 dB
Rated voltage
100 VAC
100 VAC
Average power
150 W
250 W
Maximum power
300 W
450 W
Maximum joint speed
30 RPM
30 RPM
Joint acceleration
5 rad/s2
5 rad/s2
Max tool center point (TCP) velocity
2 m/s
2 m/s
Acceleration time 0-1 m/s
0.1 s
0.1 s
1) The specification values can vary, depending on the customer precise requirements. There is a possibility to extend the reach,
increase the weight and the payload, and to add a seventh degree of freedom.

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Figure 1-3 and Table 1-3 illustrate the dimensions of the arm's six axes for PULSE 75 and
PULSE 90 models.
Figure 1-3: Lengths of the robotic arm axes
Table 1-3: Variations of a1 and a2 lengths for PULSE models
Model
a1, mm
a2, mm
PULSE 75
375
295
PULSE 90
450
370

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Table 1-4 contains motion ranges for each of the axes.
Table 1-4:Motion ranges and maximum speeds of the robot axes
Axis
Motion range
Maximum speed
Axis 1 (base)
-360° to 360°
180°/s
Axis 2
-360° to 360°
180°/s
Axis 3
-160° to 160°
180°/s
Axis 4
-360° to 360°
180°/s
Axis 5
-360° to 360°
180°/s
Axis 6
-360° to 360°
180°/s
Figure 1-4 illustrates the workspace of the PULSE robotic arm.
Figure 1-4:Workspace of the PULSE robotic arm
The cylinder-shape area of 0.12 m in diameter around the robot base is the infinite
solutions area. It is advisable to avoid programming any arm or work tool moves
within the area.
Table 1-5 contains the R1 and R2 workspace values for PULSE 75 and PULSE 90.

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Table 1-5: PULSE workspace for six and five DOF
Model
R1, m
R2, m
PULSE 75
0.67
0.83
PULSE 90
0.82
0.98
1.5 Operating conditions
The PULSE robotic arm is intended for indoor use only. When operating it, make sure to comply
with the following requirements:
Ambient temperature: 0°C to +35°C
Humidity: 80%
Altitude: max. 1,000 m above the sea
1.6 Control box
In the PULSE robotic arm system, the control box monitors and controls operation of the arm,
providing an interface for communication between hardware and software components.
The control box is a case of the dimensions as indicated in Table 1-6. It comprises a personal
computer (PC) module with pre-installed control software (PULSE DESK), as well as other
modules that perform communication, safety, and other essential functions.
Table 1-6: Specifications of the control box
Specification
Value
Weight
9 kg
Dimensions (D x W x H)
283 x 483 x 91 mm
Noise level
Less than 60 dB
Protection rating
IP21
Interfaces
4 digital inputs, 2 digital outputs
1 USB port
1 Ethernet port (RJ-45, 100 BASE-T)
API implementation options
REST API/ Python
Attention! A specific control box is compatible only with a specific robotic arm from the same
supply package.
After you start a PULSE arm, the control box compares the arm ID saved in its memory with that
of the currently connected arm. When the two IDs match, the initialization of the arm continues
in the normal way. When the two IDs do not match, the arm fails to initialize. The control box
beeps three times, and the red LED on the control box turns on.

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1.6.1 The front panel
On the front panel of the control box, there are two light-emitting diodes (LED)—a green and a
red one (see Figure 1-5).
Figure 1-5:The front panel of the control box
The front panel LEDs signal different states of the robotic arm as described in Table 1-7.
Table 1-7:LEDs on the front panel of the control box
Purpose
State / event
in the robotic arm system
LED color
Mode
Signals system states
System switched off
Green
LED off
Bootup
blinking
Ready
constantly ON
Work
constantly ON
System shutting down
constantly ON
LED state by default
constantly ON
Error
blinking
Signals errors
System switched off
Red
LED off
LED state by default
LED off
Error
constantly ON
1.6.2 The back panel
On the back panel of the control box, you can find the following:
all major connectors of the robotic arm system
a power switch
four holes for rack mounting

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Figure 1-6:The back panel of the control box
No.
Intended use
1
4 digital inputs and 2 digital outputs (for details, see Section 2.3.2)
2
USB 2.0 port
3
Ethernet port (for specifications, see Table 1-6)
4
Power supply switch
5
220 V power cable connector
6
Connector for an emergency stop button
7
48 V connector for the cable between the control box with the robotic arm
8
mounting holes
1.6.3 Sound signals
Apart from the light indication on the front panel, the control box produces beeping signals to
indicate certain system events as described in Table 1-8.
Table 1-8: Sound signals of the control box
System event
Signal
At initialization, to signal successful bootup of the operating system on the PC
module
One beep
To signal that initialization of the motors in the arm joints is completed
successfully
One beep
1.7 Emergency stop button
For the PULSE robotic arm, the emergency stop button is supplied as a standalone device pre-
assembled with a connection cable. The button is designed to provide Category 1 Stop in

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accordance with ISO 10218-1—a controlled stop with power supplied to the servo motors in the
arm joints until full stop is achieved.
Figure 1-7:The emergency stop button
The actual appearance of the emergency stop button can differ from that shown in
Figure 1-7.
Each robotic arm installation must have its own emergency stop button. You can place the button
at any location within the operator's reach.
Use the button to immediately stop the robotic arm in an emergency, when other protective
measures have proved to be impracticable or inefficient.
To resume operation of the robotic arm after an emergency shutdown, reset the system as
described below:
1. Wait for the arm to come to a full stop. The LED on the arm's wrist should go off.
2. Unpress the emergency stop button.
3. Flip the power switch on the back panel of the control box to the off position or unplug
the power cord from the mains socket.
4. Switch the system on again as described in Section 3.
Before restarting the system after an emergency shutdown, make sure the emergency
stop button is unpressed. Otherwise, the system fails start, causing the red LED on
the control box to light up.

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1.8 Wrist
The robotic arm is supplied pre-assembled with a wrist—a special flange for integrating an end
effector.
An end effector is a tool or a device designed to enable the robotic arm to perform
various operations as required for its intended application. End effectors are beyond
the scope of Rozum Robotics supply.
Figure 1-8: The wrist of the PULSE arm
The wrist of the PULSE robotic arm features:
a standard ISO 9409-1-50-4-M6 mechanical interface (1)
a cable output (2) for connecting an end effector electrically
a LED indicator (3)
When an installation requires a mechanical interface different from the standard ISO
9409-1-50-4-M6 one, the user (integrator) has to provide a proper adaptor for
integrating an end effector.
The states of the wrist LED are as described in Table 1-9.
Table 1-9: Arm states vs. LED signals
Arm state
LED signal
Power off
Off (no indication)
Standby mode (freeze state)
Green on
Operation (in motion)
Blinking green
Learn mode
Steady yellow
Error
Steady red
A control button pressed
Blinking blue

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1.9 Control buttons
For the current robot design (intended for use together with a gripper work tool), control buttons
are located on the elbow fitting above the wrist (see Figure 1-9).
Figure 1-9: Control buttons on the PULSE arm
The functions of the buttons are as described in Table 1-10. For more details about using the
buttons to operate the arm, refer to “PULSE DESK. OPERATOR MANUAL.”
Table 1-10: Functions of the control buttons
Name
Function
Free Drive mode
To enable/ disable Free Drive mode (in the mode, the user can teach an arm
different trajectories by moving its axes by hand)
Point
To add points to a program running in the PULSE DESK software
Open gripper
To open the gripper attached to the wrist
Close gripper
To close the gripper attached to the wrist
2INSTALLATION
2.1 General requirements
The PULSE robotic arm is partly completed machinery, which means its safe operation largely
depends on the operating environment. Therefore, it is common practice to conduct a risk
assessment of the operating environment for each particular installation.

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The risk assessment is the responsibility of the integrator. Based on its results, the integrator
determines whether additional safety measures (e.g., safeguards) are needed to protect the operator
working with the robotic arm in the installation.
Before installation, carry out the following preparatory works:
1. Unpack the robotic arm and other components.
2. Check the supply package against the list in Section 1.3.
3. Check the appearance of the robotic arm and other components for any damages or defects.
If you find any obvious damages or defects or find out that any of the supply package
components is missing, contact the dealer or the manufacturer.
When unpacking and installing the robotic arm, make sure not to move or rotate the
robot joints manually because this can cause damage to the arm.
Installation of the PULSE robotic arm requires completing the following two steps:
1. Mechanical integration
2. Electrical integration
2.1.1 Continuous power supply requirement
For safety reasons, the integrator shall be obliged to provide continuous power supply to the
robotic arm (e.g., installing an uninterruptible power supply, a redundancy circuit, etc.). Otherwise,
we cannot guarantee that the robotic arm maintains its position during a power outage, which may
result in serious damage to its components.
2.2 Mechanical integration
Pinching hazard! When performing mounting works, keep your fingers away from
the arm joints to avoid entrapment. Do not wear loose clothing or jewelry. Make sure
long hair is tied back.
2.2.1 Mounting the robotic arm
Though the footprint of the PULSE robotic arm is as small as 120 mm (see Figure 2-1), you need
to account for the arm workspace (Figure 1-4) when choosing a mounting location. This is
important to exclude collisions with other equipment or objects.
The recommended mounting position for the PULSE robotic arm is vertical, on a horizontal
immovable surface. The mounting surface should be:
flat, solid, and stable
sustain 8 times the weight of the robotic arm (see Table 1-2)

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The installation procedure includes the following steps:
1. Position the robot arm vertically.
2. Holding the arm tight, secure it on a mounting surface using one of the following methods:
Method 1.
-Insert 4 M8 bolts into the four 9-mm dia. holes on the transition plate (see Figure 2-1)
and tighten the bolts up as appropriate.
Figure 2-1: Mounting the arm by Method 1
Method 2.
-Since the arm is supplied pre-assembled with a transition plate, your first step is to
dismantle the plate. To do this, unscrew the 2 pins and 11 bolts holding the arm base and
the transition plate together.
-Use the 2 pins and 11 bolts (see Figure 2-2) to screw the arm base down to your mounting
surface without a transition plate.
Figure 2-2: Mounting the arm by Method 2

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2.2.2 Installing the control box
There are three methods to install the control box:
horizontal positioning on a flat solid surface (e. g., a table)
vertical positioning using a specially designed stand
rack mounting (DIN 19") (for location of rack mounting holes, see Figure 1-6)
The exact installation method depends on the particular operating environment of the PULSE
robotic arm and your requirements. In any case, the distance from the control box to the robotic
arm should not exceed 3 meters—the length of the connection cable. Otherwise, you will have to
use a cable extension.
When installing the control box, provide an air gap of 50 mm from its front and back
panels.
2.3 Electrical integration
Before proceeding to any electrical integration works, make sure no power is supplied
to the robotic arm or the control box.
All major connections required to provide electrical integration of the robotic arm into your
application are located on the back panel of the control box (see Figure 1-6).
2.3.1 Power connection
The power connection of the control box is in accordance with the IEC 60320-1 C14 standard. The
electrical specifications are as indicated in Table 2-1.
Table 2-1:Electrical specifications of the control box power connection
Parameter
Value/ range
Unit
Input voltage
100–264
VAC
Mains frequency
47–63
Hz
Standby power
10
W
Average operating power
400
W
For enhanced safety, consider installing an external mains switch with a fuse.
2.3.2 Digital I/O connectors
The control box has four digital inputs and two digital outputs that you can use to connect
additional equipment, including sensors, safety devices, PLC, etc. The connectors are located on
the back panel of the control box (see Figure 1-6).
The cable length from the digital inputs/ outputs to connected equipment should not
exceed 2 m. Otherwise, signal quality may suffer.

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For the current control box configuration, the two lower digital I/O connectors have the
RESERVED status. The pin assignment for the two upper ones is as illustrated in Figure 2-3.
Figure 2-3:Pin assignment for digital I/O connectors
Table 2-2:Specifications of relay outputs
Relay output 1
Relay output 2
Description
Specifications
COM1
COM2
Common
Contact capacity: 48 V, 0.5 A
NC1
NC2
Normally closed
NO1
NO2
Normally open
Table 2-3:Specifications of digital inputs
Digital input
Description
Specifications
12 V DC
Power for an external device
Max current load: 1 A
Warning! Connecting inductive load
can cause damage to equipment!
GND
Ground, 0 V
DI1, DI2, DI3, DI4
Digital input
Max permissible current: 35 mA
Input voltage range (Hi level): 5-12 V
Input voltage range (Low level): 0-1.5 V

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2.4 Mounting an end effector
Depending on particular needs, you can use different end effectors with the PULSE robotic arm.
Possible options include grippers for pick-and-place operations, material removal tools for cutting,
drilling, and deburring, welding torches, etc.
Selecting a proper type and model of an end effector is the responsibility of the
integrator.
To attach an end effector to the robotic arm, use the mechanical and electrical interfaces on its
wrist (see Figure 1-8). In its basic design, the wrist of the PULSE robotic arm has the standard
ISO 9409-1-50-4-M6 mechanical interface as shown in Figure 2-4.
For more details, refer to the dimensional drawing, which is available for downloading
at the web page: https://rozum.com/pulse-documentation/.
Figure 2-4:Basic mechanical interface on the arm wrist
In case your end effector has a mechanical interface different from the standard ISO
9409-1-50-4-M6 one, make sure to use an appropriate adaptor.
The basic electrical interface of the arm wrist is a socket as shown in Figure 2-5.
Figure 2-5:Basic electrical interface on the arm wrist