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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  • Warning
  • Caution

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  1. About this manual

Safety precautions

To ensure proper product use and user safety and to prevent property damages, make sure to read and fully understand the following precautions before using the product.

Danger

[Danger] impending risk: If not conformed to, operator deaths or severe injuries may occur.

  • Perform a risk assessment on the entire system, not the individual devices. Connecting other devices to the product may increase the risk level of the product or create new risks. If the devices of the integrated robot system have different risk levels, prepare safety devices based on the device with the highest risk level in preparedness for risks.

  • In installing the robot product and other devices, make sure to read, fully understand, and conform to the product installation instructions described in the manual.

  • In case of any issues of the product, such as faults and damages, stop using the product immediately and contact our Customer Support Team.

Warning

[Warning] Potential risk: If not conformed to, operator injuries or property damages, including serious product damages, may occur.

  • Take adequate safety measures according to the result of risk assessment, and accurately assign the safe range of robot installation. During the robot operation, product damages or user injuries may occur.

  • Persons who manufacture robot application systems or use the robot must read and fully understand the manual and undergo training in robot operation.

  • For the safety of operators and users, prepare adequate safety facilities such as safety fences before installing the product.

  • Secure sufficient space so that the robot arm can move freely. During the robot operation, product damages or user injuries may occur.

    Fasten locking bolts to the specified torque according to the specification sheet. Loose bolts may lead to damages of the robot because of falling from the installation position.

  • Pay attention to the product connections (power and cables) so that no conductive substances, such as liquid, dust, and metal particles, could infiltrate. Do not poke the connection with sharp objects or apply excessive force during cable connection. Corrosion or temporary short circuits of connectors may lead to product explosion or fires.

  • Check the wiring specification and connect devices with terminals that are suitable for the device types. Make sure to connect safety devices to dedicated terminals because connecting them to general terminals does not guarantee safety functions.

  • Never use damaged cables and do not disconnect cables while the product is in use. Doing so may lead to electric shocks, fires, faults, and injuries.

  • Long-time use of the product may lead to overheating and cause injuries such as burns. In the event it is necessary to touch the product, cool down the product sufficiently by powering it off and leaving it for at least one hour.

  • Never arbitrarily install, modify, disassemble, or repair the product. This may lead to faults and accidents. Hyundai Robotics will not take responsibility for product damages caused by such arbitrary actions.

Caution

[Caution] Minor risk: If not conformed to, minor operator injuries or property damages, including product damages, may occur.

  • Do not arbitrarily install, modify, disassemble, or repair the product. It is prohibited for persons other than experts from Hyundai Robotics to modify or attach parts to the product. Product faults caused by it will void free-of-charge services and warranty services.

  • In the event it is necessary to install or repair the product, contact our Customer Support Team to consign the work to experts.

  • Do not install or use the product at a place filled with dust or dirt. Dust or foreign matters may lead to product faults or malfunctions.

  • Do not install or use the product at a place of magnetism, a place which is affected by magnetism, or a place of electromagnetic interferences. Magnetism may lead to product damages or malfunction.

  • In operating the product, do not wear loose clothes or accessories. If you have long hair, you should tie it at the back of your head so it will not entangle between joints and the like of the robot.

  • While the product is in operation, do not enter its operating range or touch the robot. Doing so may lead to injuries.

  • Transport the product as it is packaged to prevent product damages, and store it at a dry and low-humidity place. Storing it at a humid place may lead to product damages or faults caused by moisture infiltration.

  • Store the product at a place that is clean, cool, dry, and free from high variation in temperature and humidity.

  • The product should be moved by two or more persons, and the correct posture should be maintained. If not, the persons may be subject to physical injuries in the waist, arms, legs, and the like.

  • In moving the product using lifting equipment, conform to the local and national safety regulations and the instructions for equipment use.

  • Before moving the product, read and conform to the moving instructions specified in the manual. Hyundai Robotics will not take responsibility for product damages caused during transportation by the customer.

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