Maintenance Manual for Collaborative Robot
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  • Maintenance Manual for Collaborative Robot
  • About this manual
    • Copyright
    • Notation rules
    • Safety precautions
  • 1. Safety
    • 1.1 Safety requirements
      • 1.1.1 Applicable standards
      • 1.1.2 Safety performance
    • 1.2 Safety measures
      • 1.2.1 Safety functions
      • 1.2.2 Safety training
      • 1.2.3 Safety labels
      • 1.2.4 Emergency stop
        • 1.2.4.1 Emergency stop switches
        • 1.2.4.2 Connecting to emergency stop devices of external systems
    • 1.3 Risk assement
    • 1.4 Potential risk
    • 1.5 Validity and responsibilities
  • 2. Introduction to the product
    • 2.1 Intended uses of the product
    • 2.2 Product components
    • 2.3 Part names
      • 2.3.1 Manipulator
      • 2.3.2 Controller
      • 2.3.3 Teach pendant
    • 2.4 Nameplate
  • 3. Product installation
    • 3.1 Environment of installation and preparation
      • 3.1.1 Environments of installation and use
      • 3.1.2 Spaces of the robot system
      • 3.1.3 Allowable limit of wrist axis load
      • 3.1.4 Payload
    • 3.2 Product installation
      • 3.2.1 Composition of robot systems
      • 3.2.2 Robot and controller installation
        • 3.2.2.1 Mounting plate installation
      • 3.2.3 Tool connection
      • 3.2.4 Wiring
      • 3.2.5 Power on
    • 3.3 Robot interface
      • 3.3.1 Tool flange connection point
        • 3.3.1.1 T4071017041-001 (TE) pin map
        • 3.3.1.2 T41171130012-001 (TE) pin map
        • 3.3.1.3 Air hose
      • 3.3.2 External device interface
        • 3.3.2.1 Terminal block (TB1): common analog I/O signals
        • 3.3.2.2 Terminal block (TB2): dedicated safety signal input
        • 3.3.2.3 Terminal block (TB3): system signal I/O
        • 3.3.2.4 D-sub 25-pin connector (SDIO): common digital I/O
        • 3.3.2.5 D-sub 9-pin connector (COM1, COM2): serial communication (RS485, 422)
    • 3.4 Stopping distance and time
      • 3.4.1 STOP 0
      • 3.4.2 STOP1
    • 3.5 Safety setting
    • 3.6 Programming and restarting
    • 3.7 Axis limiting devices
    • 3.8 Movement without drive power
    • 3.9 Other safety precautions
  • 4. Maintenance
    • 4.1 Checking of the collaborative robot
      • 4.1.1 Check sheet
      • 4.1.2 Wiring check
      • 4.1.3 Bolt check
    • 4.2 Maintenance of the collaborative robot
      • 4.2.1 Replacement of internal wiring
      • 4.2.2 Replacement of the integrated driving module
        • 4.2.2.1 Replacement timing
        • 4.2.2.2 Weight of the integrated driving module
        • 4.2.2.3 Tools and parts
        • 4.2.2.4 Recommended posture in disassembling the integrated driving module
        • 4.2.2.5 Method for replacing the integrated driving module
      • 4.2.3 Encoder backup battery replacement
      • 4.2.4 Grease replacement
    • 4.3 Controller check and maintenance
      • 4.3.1 Internal structure
      • 4.3.2 Safety control module
        • 4.3.2.1 Connection and display
        • 4.3.2.2 Connection of I/O signals for the robot system (TBSYS1)
        • 4.3.2.3 Safety I/O signal connection (TBSDI, TBSDO)
        • 4.3.2.4 Connection of common digital I/O signals (TBDIO)
        • 4.3.2.5 Connection of common digital I/O signals (TBAIO)
        • 4.3.2.6 Information on major components
      • 4.3.3 Power precharge module (PPM)
        • 4.3.3.1 Connection and display
        • 4.3.3.2 Information on major components
      • 4.3.4 Regenerative discharge module (RDM)
        • 4.3.4.1 Connection and display
        • 4.3.4.2 Information on major components
      • 4.3.5 Microcomputer module
      • 4.3.6 Power supply
      • 4.3.7 Teach pendant
      • 4.3.8 PCI communication card (optional)
        • 4.3.8.1 Connect pin map
  • 5. Moving and storing
    • 5.1 Moving method
      • 5.1.1 Recommended posture
      • 5.1.2 Packaging box
      • 5.1.3 Cautions
    • 5.2 Storing method
    • 5.3 Disposal
  • 6. Appendix
    • 6.1 Block diagrams
      • 6.1.1 YL012 S-axis
      • 6.1.2 YL012 H-axis
      • 6.1.3 YL012 V-axis
      • 6.1.4 YL012 R-axis
      • 6.1.5 YL012 B-axis
      • 6.1.6 YL012 R1-axis
      • 6.1.7 YL012 tool flange
      • 6.1.8 Power connector
    • 6.2 System specifications
      • 6.2.1 Collaborative robot
      • 6.2.2 Controller
      • 6.2.3 Teach pendant
  • Certifications
  • Attachment
    • Rules on Occupational Safety and Health Standards, and Notice for Safety Inspection
  • Quality Assurance
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  1. 3. Product installation
  2. 3.3 Robot interface
  3. 3.3.2 External device interface

3.3.2.4 D-sub 25-pin connector (SDIO): common digital I/O

Previous3.3.2.3 Terminal block (TB3): system signal I/ONext3.3.2.5 D-sub 9-pin connector (COM1, COM2): serial communication (RS485, 422)

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You can connect digital I/O signals for external safety signals, eight at a time, to the D-sub 24-pin connector (SDIO). For more details on signal connection, see “General purpose safety I/O signals.”

Set the safety I/O signals according to usages, referring to “” For example, if you will not use the teach pendant and will use an enabling switch, connect it to the common safety signal input and assign input signals. The types of I/O signals that can be assigned are as follows:

  • Input signals: STOP0, STOP1, STOP2, SOS, Reduced mode, Enable SW, Motor on, Mode switch-manual, Mode switch-auto, Mode switch-remote, Cartesian space #1 - #12

  • Output signals: STO activation status, SOS activation status, Reduced mode activation status, Not reduced mode, Robot moving, Robot not stopping, Mode switch-manual, Mode switch-auto, Mode switch-remote, Cartesian space status #1 - #12, Violation alarm, TCP speed violation, TCP orientation violation, TCP force violation, Collision detection, Momentum violation, Power violation, SOS violation, Joint position violation, Joint speed violation, Cartesian space violation #1 - #12

Pin number

1

2

3

4

5

Name

SDIN0

SDIN1

SDIN2

SDIN3

SDIN4

Usage

Safety signal input 0

(Channel 1)

Safety signal input 1

(Channel 1)

Safety signal input 2

(Channel 1)

Safety signal input 3

(Channel 1)

Safety signal input 4

(Channel 2)

Internal connections of the controller

SCM TBSDI

Pin 9

SCM TBSDI

Pin 10

SCM TBSDI

Pin 11

SCM TBSDI

Pin 12

SCM TBSDI

Pin 13

Pin number

6

7

8

9

Name

SDIN5

SDIN6

SDIN7

SIO_POW1

SIO_POW2

Usage

Safety signal input 5

(Channel 2)

Safety signal input 6

(Channel 2)

Safety signal input 7

(Channel 2)

Safety signal input common (Channel 1)

Safety signal input common (Channel 1)

Internal connections of the controller

SCM TBSDI

Pin 14

SCM TBSDI

Pin 15

SCM TBSDI

Pin 16

SCM TBSDI Pin 1, 2

SCM TBSDI Pin 3, 4

Pin number

11

12

13

14

15

Name

SIO_POW3

SIO_POW4

-

SDOUT0

SDOUT1

Usage

Safety signal input common (Channel 2)

Safety signal input common (Channel 2)

-

Safety signal output 0 (Channel 1)

Safety signal output 1 (Channel 1)

Internal connections of the controller

SCM TBSDI Pin 5, 6

SCM TBSDI Pin 7, 8

-

SCM TBSDO

Pin 9

SCM TBSDO

Pin 10

Pin number

16

17

18

19

Internal of the controller

11

12

13

14

Name

SDOUT2

SDOUT3

SDOUT4

SDOUT5

Usage

Safety signal output 2 (Channel 1)

Safety signal output 3 (Channel 1)

Safety signal output 4 (Channel 2)

Safety signal output 5 (Channel 2)

Internal connections of the controller

SCM TBSDO

Pin 11

SCM TBSDO

Pin 12

SCM TBSDO

Pin 13

SCM TBSDO

Pin 14

Pin number

21

22

23

24

25

Internal of the controller

16

1, 2

3, 4

5, 6

7, 8

Name

SDOUT7

SIO_GND1

SIO_GND1

SIO_GND2

SIO_GND2

Usage

Safety signal output 7 (Channel 2)

Safety signal output common (Channel 1)

Safety signal output common (Channel 1)

Safety signal output common (Channel 2)

Safety signal output common (Channel 2)

Internal connections of the controller

SCM TBSDO

Pin 16

SCM TBSDO Pin 1, 2

SCM TBSDO Pin 3, 4

SCM TBSDO Pin 5, 6

SCM TBSDO Pin 7, 8

[Caution]

  • Separate safety signals and common I/O signals, and never connect safety signals to other PLCs than safety PLCs. If you connect safety signals to other PLCs, it will lead to the malfunction of the safety stop function and may cause safety accidents, including physical injuries.

  • All the I/Os of safety grade are of redundancy structure. Make sure to separate the relevant channels to prevent signal faults from compromising the safety function.

  • Make sure to power off the product before carrying out any types of wiring, termination, and electrical work.

  • Hyundai Robotics will not take responsibility for product damages caused by the customer’s carelessness, unskillful operation, and other errors. Never arbitrarily modify, disassemble, or repair the product.

  • Make sure to check the safety functions before robot installation and check for anomalies at regular intervals afterward.

This signal is connected to the Safety control module installed inside the controller. For more details on signal connection, refer to “.”

4.3.2.3 Safety I/O signal connection (TBSDI, TBSDO)
Safety Function Manual for Collaborative Robots.
Figure 24 Method for connecting universal safety input and output signals
Figure 25 Method for connecting universal safety input and output signals (PLCs)