Summary of Contents for fruitcore robotics HORST600
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Robot System HORST600 Assembly Instructions For installation, operating, and maintenance personnel Always keep with the product! Version 3.1 / 09.02.2022...
Contents Introduction ......................... 1 Principle ............................1 General Information ........................1 Operating Responsibility and Liability ..................1 1.3.1 Legal Disclaimer ......................2 Warranty ............................2 Organizational Measures ......................2 Applied Standards and Regulations ................... 2 Signs, symbols ..........................3 Marking of the Safety and Warning Signs ................3 Safety ..........................
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Protection Devices ........................24 4.3.1 Enabling switch ......................24 4.3.2 Emergency Stop Button ..................... 24 Add-on Parts & Tools (Option) ....................24 Assembly ........................25 Working Area of the Robot ......................25 Assembly of the Robot ....................... 26 5.2.1 Mounting Surface ......................26 5.2.2 Assembling the Robot ....................
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Shutdown after End of Operation ..................... 63 Fault Rectification ....................65 10 Cleaning and Maintenance ..................66 10.1 Cleaning ............................66 10.2 Maintenance and Repair ......................67 11 Storage ........................68 12 Disassembly and Disposal ..................69 12.1 Disassembly ..........................69 12.2 Disposal ............................
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List of Tables Table 6-1: Mains connection characteristic values ......................32 Table 6-3: Configurable functions for safe inputs ......................38 Table 6-4: Configurable functions for safe outputs ......................39 Table 6-5: Test signal characteristic values ........................39 Table 6-6: Configurable functions for general digital inputs ..................40 Table 6-7: Configurable functions for general digital outputs ..................
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List of abbreviations Microseconds µs High, Logical 1 Highly Optimized Robotic Systems Technology HORST Input/Output Kilovolt Kilo ohm kΩ Low, Logical 0 Milliampere milliseconds Milli ohm mΩ Output Switching Signal Device OSSD Tool Center Point Ω...
1 Principle Introduction Principle The Assembly Instructions contain important information on how to operate the robot system in a safe, proper, and economically efficient way. Adherence to these Assembly Instructions helps to avoid hazards, reduce repair costs and downtime, and to increase the reliability and service life of the robot system. The operator is obligated to add instructions arising from existing national or company regulations on accident prevention and environmental protection to the Assembly Instructions.
Unless otherwise agreed upon in the purchase contract, we will grant the legally prescribed warranty pe- riod for the robot system and spare parts, starting on the day of delivery. The warranty provisions specified in the general terms and conditions of fruitcore robotics GmbH or the individual purchase contract apply in addition.
1 Signs, symbols Signs, symbols The following symbols are used in the Assembly Instructions: Lists Simple lists are marked with “–”. − Instructions for action All instructions for action for a procedure are listed in chronological order. Instructions are marked with “ ”.
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1 Marking of the Safety and Warning Signs ELECTRICAL VOLTAGE! This sign is a warning for electricity. It is posted for all work and operating procedures that are to be observed precisely in order to prevent danger to persons and the system by electricity. ATTENTION! Danger of damage to robot or property.
2 General Safety Information Safety General Safety Information The HORST robot system is a quality product manufactured in accordance with the recognized rules of technology. The robot system left the manufacturing plant in perfect condition in terms of safety. The robot system is designed and built according to the current state of the art in safety technology. However, there is always a residual risk! For your own safety, always observe the following: WARNING!
2 Improper Use Improper Use Any use that is not described in section 2.2 or goes beyond it is considered improper use. 2.3.1 Foreseeable Misuse The robot system is not intended for hazardous applications. Any use or application that deviates from the intended use is considered as impermissible misuse.
2 Operator’s Duties Operator’s Duties 2.4.1 EU Declaration of Conformity and Declaration of Incorporation The robot system is considered partly completed machinery in accordance with the EC Ma- chinery Directive. The robot system must be commissioned only under the following condi- tions: 1.
− to check the robot system in terms of safety and proper function before starting work. − − to contact the operations manager or fruitcore robotics GmbH in case of questions. 2.5.2 Training of the Operating Personnel DANGER! Possible personal injuries caused by untrained operating personnel ...
2 Safety Functions DANGER! Due to the robot’s automatic movement, sudden dangers must be expected within the danger zone. Moving modules may cause personal injury or property damage. The robot system must be operated only in technically perfect condition and with active safety equipment.
Danger due to incorrect assembly and commissioning Assembly and commissioning must be performed only by persons with technical and elec- trotechnical training who were also authorized by fruitcore robotics GmbH. DANGER! Danger due to missing protection devices and safety equipment as well as defective/damaged modules or accessories.
Do not enter the danger zone of the robot during operation, and do not touch the robot. Only operate the robot system in undamaged condition. Never modify the robot system. fruitcore robotics GmbH excludes any liability if the product has been modified. Check the emergency stop and safety stop functions daily.
2 Safety Information on Operation In the event of an emergency, the robot system must be stopped with the emergency stop button (see Emergency subsection Stop Button, page 24). When integrated in a complete system, the robot system must be integrated in the emergency Safety- stop circuit of the higher-level system.
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Then secure the robot arm again against unintended movements. Attention: The warranty expires when this action is performed and the robot system must only be started up again after consultation with fruitcore robotics GmbH. DANGER! Defective and damaged components and modules / faulty assembly After manual movement of the robot arm, the robot system must not be started up again.
Maintenance and inspection intervals stipulated in the Assembly Instructions, including the replacement of wear and spare parts, must be observed. Spare parts must correspond to the technical requirements specified by fruitcore robotics GmbH. This is always guaranteed with original spare parts.
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2 Residual Danger DANGER! Danger resulting from human error or malfunctions When integrated in a complete system, the robot system must be integrated in the emer- gency stop circuit of the higher-level system. WARNING! Operation without protection devices presents a risk of injury ...
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2 Residual Danger DANGER OF CRUSHING, IMPACT AND CUTTING! Possible personal injuries due to the robot arm collapsing during maintenance work If a belt tears unexpectedly, the robot arm may collapse. During maintenance work, the robot arm must be sufficiently secured against collapsing. ...
Securely package the robot, horstPANEL, and horstCONTROL. During further transport, the robot system must be secured against toppling over and falling down. ATTENTION! For transport, the robot system must be in the original packaging from fruitcore robotics GmbH.
4 Scope of Delivery Description of the Robot System In this section, we will describe the robot system and its components. Scope of Delivery The robot system is delivered with: HORST robot − − horstCONTROL (switch cabinet) horstPANEL (portable operating panel) −...
4 Modules Modules In this subsection, the main modules of the robot system are presented. The most important components are listed and some are explained in more detail. 4.2.1 Robot Fig. 4-1: Robot HORST 600 Base – fixed part with floor flange Base –...
It is connected to the horstCONTROL by a DVI cable. As standard, a 5 m long DVI cable is supplied. Up to 15 m are possible after consultation with fruitcore robotics GmbH. Fig. 4-3: horstPANEL operating panel...
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4 Modules 2x USB 2.0 ports Enabling switch The enabling switch and two USB 2.0 ports for connecting additional input devices (keyboard, mouse) are located on the rear. The USB ports on the horstPANEL are intended only for connecting input devices. Use the USB port on the horstCONTROL to connect storage media.
4 Modules 4.2.3 horstCONTROL (switch cabinet) The horstCONTROL is the robot’s control system. The main control (horstIO) is installed in this switch cabinet. Countless interfaces also enable communication with and control of other machines and exter- nal sensors and actuators. The left-hand image shows the front side of the horstCONTROL, and the right-hand image shows the rear side.
4 Protection Devices Protection Devices 4.3.1 Enabling switch The enabling switch is executed in three stages. The center position is “active”. Enabling switch The enabling switch is on the rear side of the horstPANEL. Fig. 4-7: Rear side of horstPANEL 4.3.2 Emergency Stop Button When integrated in a complete system, the robot system must be integrated in the emergency...
5 Working Area of the Robot Assembly Working Area of the Robot The following figures display the size and shape of the working area. Fig. 5-1: Side view of working area Fig. 5-2: Plan view of working area...
Danger due to incorrect assembly and commissioning Assembly and commissioning must be performed only by persons with technical and elec- trotechnical training who were also authorized by fruitcore robotics GmbH. CAUTION! Risk of injury due to the robot falling ...
5 Assembly of the Robot 5.2.2 Assembling the Robot Fig. 5-3: Base plate – Mounting and positioning holes Prepare the mounting surface according to the drilling pattern (see Fig. 5-3). Lift the robot by the swivel arm and position it on the prepared mounting surface. ...
5 Assembling Add-on Parts The stop bolt (1) is at the rear of the base Undo the screws (2) of the cover Remove the cover (3) Bring the robot into position so that the thread of the desired stop position is accessible from above ...
5 Setting Up horstCONTROL Refer to the Annex for information on optional add-on parts from fruitcore robotics GmbH. For information on add-on parts from third-party manufacturers, refer to their documentation. Add-on parts (e.g. pneumatic valves) can be fitted on the robot arm after consultation with fruitcore robotics GmbH.
6 Electrical System Warning Notes Electrical Installation This section describes the electrical installation of the robot system, i.e. the connection of the robot to the switch cabinet (horstCONTROL) as well as the connection of other devices and systems. There are several electrical interfaces: Robot connection: Connection of the robot to the horstCONTROL (switch cabinet) −...
6 Robot Connection WARNING! Trip hazard Ensure that the cables and hoses for media and power supply are properly laid and secured. WARNING! Unexpected movements of the robot Only connect the power supply when you are certain that assembly has been fully completed and is correct.
6 Power Connection Power Connection The horstCONTROL power connection is a standard IEC C14 male socket (IEC-60320) with integrated pull-out protection. The supplied power cable has a safety plug at one end and an IEC C13 cold-device coupling with specially molded housing at the other end. This, together with the pull-out protection, en- sures reliable connection to the power supply.
6 horstCONTROL I/O horstCONTROL I/O This section describes how to connect devices to the horstCONTROL. The connections can be split into four categories: Safety-critical inputs/outputs − − General digital outputs +24 V power supply − Add-on interface − The inputs and outputs for this are located on the horstIO – the main control installed in the horstCON- TROL –...
6 horstCONTROL I/O 6.4.1 Overview of All Interfaces The following graphic shows the layout of the interfaces available on the horstIO. Fig. 6-5: horstIO interfaces 7 safety-critical inputs – 2-channels each (orange area) − 3 dedicated inputs (orange area with red font) Emergency stop input –...
6 horstCONTROL I/O 6.4.2 Safety-critical Inputs/Outputs The horstCONTROL is equipped with several safe inputs and outputs. Safe I/Os are established redun- dantly through two independent lines. An incident or failure of a line therefore does not result in the com- plete loss of the safety function.
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6 horstCONTROL I/O Output Signal Switching Device (OSSD) For safety-critical inputs, an output signal switching device (OSSD) can be activated. With an output signal switching device activated, the output is periodically switched off and the input read back. If the results do not match, an error is triggered.
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6 horstCONTROL I/O 6.4.2.2 Enabling Switch I/O The Enable input (ENA, ENB) is another dedicated input (Safety In 3), which is intended exclusively for a three-stage enabling device (enabling switch) and therefore cannot be configured. The enabling switch of the horstPANEL is con- nected to the safe inputs at terminals X3.5 and X3.7 in the lower half of terminal block X3, and to the control system at terminals X3.6 and X3.8.
6 horstCONTROL I/O Software Configuration Options for The following functions can be configured for the safe inputs (see Digital Interfaces, page 44): Function Stop Description category None Emergency stop Signals an internal emergency stop Emergency stop output is set. External emergency stop External system signal emergency stop.
6 horstCONTROL I/O Software Configuration Options for The following functions can be configured for the safe outputs (see Digital Interfaces, page 44): Function Description None Emergency stop “LO”: The robot is in emergency stop (internal emergency stop or trig- gered by an error). Robot stopped “HI”: No axis is moving.
6 horstCONTROL I/O 6.4.4 General Digital Inputs There are 20 general digital inputs available at terminal blocks X1, X2 and X3. Inputs DI01 to DI20 (Digital In) are +24 V input channels and correspond to IEC 61131-2 Type 1 and 3. Configurable Safe Inputs If the , page 37 are configured...
6 horstCONTROL I/O 6.4.5 General Digital Outputs There are 18 general digital outputs available at terminal blocks X9, X10 and X11. Outputs DO01 to DO18 (Digital Out) are +24 V output channels and can be configured as Push-Pull (switch to positive supply voltage and to ground) or High-Side switches (switch only to the positive supply voltage) via horstFX.
6 horstCONTROL I/O Safe Shut-down of the General Digital Outputs Digital outputs DO01 to DO16 are supplied by the +24 V power supply via a bridge at X17.7/X17.8. One bridge each is inserted here in the delivery state. If this bridge and the associated ground connection are routed to the connected actuators via a safety relay pair, these can be Fig.
6 horstCONTROL I/O 6.4.7 Common Features of All Digital Interfaces 6.4.7.1 Electrical Parameters The specifications described in this section apply to all digital interfaces (safety-critical and general). The Functional Wiring Diagrams functional wiring diagrams for the interfaces can be found in the Annex ( the Electrical Interfaces, page 82).
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6 horstCONTROL I/O 6.4.7.2 Software Configuration Options for Digital Interfaces Configuration of Inputs/Out- In the horstFX software, the inputs and outputs can also be configured in the puts Settings & Info menu under Assignment of Functions Function In horstFX, functions can be assigned to the general digital I/Os and the configurable safe I/Os ( assignment setting).
6 horstCONTROL I/O 6.4.8 Wiring Examples of Safety-critical Inputs/Outputs This subsection provides examples of the wiring of digital interfaces on the horstCONTROL. Other exam- ples can be found on horstCOSMOS. 6.4.8.1 Standard Safety Configuration In the delivery state, the control system is configured for sole operation of the robot.
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6 horstCONTROL I/O 6.4.8.4 Safety Stop The robot should be stopped safely as soon as the pro- tected area of a safety laser scanner is entered. The first example shows the connection of a laser scanner when using the internal test signal. This is routed to the control inputs of the laser scanner;...
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6 horstCONTROL I/O 6.4.8.5 Connecting Emergency Stop for Several Devices In a system, the robot should Robot 2 Robot 1 be integrated in the emer- gency stop circuit of the other devices so that there is no need, in an emergency, to de- cide which emergency stop button must be pressed.
6 horstCONTROL I/O 6.4.9 Wiring Examples of Digital Inputs/Outputs The following examples show the use of the general digital inputs and outputs. Fig. 6-26: Consumer at the digital output Fig. 6-27: Button at the digital input An inductive proximity switch in the configuration as a PNP normally closed contact should be con- nected to a digital input.
6 Tool I/O Tool I/O On support arm 3 of the robot, there are two interfaces (User 1, User 2), which supply current and control signals for grippers and sensors that can be mounted at the tool interface of the support arm 3. Each of these interfaces has two digital inputs/outputs as well as a +24 V power supply.
6 Tool I/O Parameter min. typ. max. Unit Description Inputs Voltage -1.5 24.3 Input voltage Switching threshold Logical high–low HI – LO Switching threshold Logical low–high LO – HI Current consump- tion IEC 61131-2 Type Outputs Function Type Push-Pull, semiconductor Voltage Output voltage Current...
6 Computer Interfaces Computer Interfaces In the horstCONTROL there is an integrated computer whose accessible interfaces are described in this sub- section. 6.6.1 PROFINET (optional) The horstCONTROL has an optional PROFINET communication interface (PROFINET IO, conformity class C), through which it is possible to exchange data between a PLC and the robot. PROFINET (Process Field Network) is a real-time capable industrial Ethernet protocol, which is used as the standard protocol in automation.
Danger resulting from incorrect commissioning Commissioning must be performed only by persons with technical and electrotechnical train- ing who were also authorized by fruitcore robotics GmbH. Before commissioning: Make sure that any transport equipment or transport securing devices have been removed.
7 Switching on the Robot System Switching on the Robot System Switch the main switch on the horstCONTROL to ON. The software (horstFX) starts up on the horstPANEL. The main menu appears on the display. Fig. 7-1: Main menu ...
7 Initializing the Robot Initializing the Robot WARNING! Danger of impact and crushing due to robot movement The safety stop function is deactivated during the initialization. During initialization operation, close off the area around the robot and protect it against ac- cess by unauthorized persons.
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7 Initializing the Robot To perform the initialization, the axes (starting with axis 6) must carry out a movement one after the other. If this is not possible, the axes must be moved manually. In this case, switch to the manual initialization menu.
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7 Initializing the Robot Fig. 7-5: Initialize robot – outputs menu Outputs can be switched manually here. For example, a gripper can be opened before the initialization drive is continued. Switch the desired output via the corresponding changeover button. The automatic/manual initialization of the axes was successful if all six dots (initialization status) for the axes are shown in turquoise.
Modules of the robot system may be damaged if the robot arm was moved manually in an emergency. This may result in an uncontrolled start-up. Have the robot system checked by the customer service of fruitcore robotics GmbH before recommissioning it.
8 Operating Modes Rectify the danger situation. A pop-up window with a warning mes- sage stating that an emergency stop was triggered appears on the display. Fig. 8-2: Emergency stop warning message Reset the emergency stop Check whether the danger has been rectified before resetting the emergency stop. ...
8 Operating Modes Operating modes selector switch Position for operating mode T1 Position for operating mode T2 Position for automatic mode Fig. 8-4: Operating modes selector switch 8.2.1 Teaching mode WARNING! Danger of impact and crushing due to robot movement The safety stop function is deactivated in teaching mode.
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8 Operating Modes T1 – programming mode The speed of the TCP (tool center point) is limited to 250 mm/s. The robot can be moved only with the enabling switch. Before programming waypoints, ensure that the system has reached operating temperature. Thermal expansion in the robot system can result in position deviations.
8 Operating Modes 8.2.2 Automatic Mode Programs are executed automatically in automatic mode. The robot acts without the enabling switch and the safety functions are active. Danger! Danger of impact and crushing due to robot movement Ensure that there are no persons within the protected area. ...
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8 Operating Modes Switch the operating modes selector switch on the horstCONTROL to automatic. Pull out the key to prevent unauthorized persons from changing the operating mode. Confirm the change of operating mode; the enabling switch must be released to do this (see horstFX user manual).
8 Shutdown after End of Operation Shutdown after End of Operation At the end of operation, the robot system must be shut down. To cancel a running program, tap the cancel program button (1). The robot is braked immediately. Fig.
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8 Shutdown after End of Operation Alternatively, you can also shut down the computer for the software (horstFX) that is integrated in the horstCONTROL as follows: horstCONTROL (switch Press the PC ON/OFF button (see subsection cabinet), page 23) on the horstCONTROL.
Confirm the fault message on the display once all causes of the fault have been removed. Call the fruitcore robotics GmbH service if you cannot remove the causes of the fault yourself. In the case of software problems, switch off the robot system as described in subsection 8.3, page 63 and switch it on again as described in subsection 7.1, page 53 .
Modules of the robot system may be damaged if the robot arm was moved manually in an emergency. This may result in an uncontrolled start-up. Have the robot system checked by the customer service of fruitcore robotics GmbH before recommissioning it.
The operating personnel must check the robot system for external damage every day. If there is a service contract with fruitcore robotics GmbH, care must be taken that the robot system data is continuously sent to horstCOSMOS, see the horstFX user manual.
11 Maintenance and Repair 11 Storage If the robot system is stored away for use at a later time or decommissioned, it must be protected with suitable packaging. The robot system must be stored in a dry, frost-protected place that is not exposed to rainfall or heavy temperature fluctuations.
12 Disassembly 12 Disassembly and Disposal 12.1 Disassembly Disassemble or secure any add-on parts. Transport Move the robot to transport position (see subsection , page 18). Shut the robot down (see subsection Shutdown after End of Operation, page 63). ...
76.5 mm (eccentricity e: 38.3 mm; offset Z: 66.3 mm) Permissible load capacity Max. 3 kg (After consultation with fruitcore robotics GmbH) The permissible load capacity is reduced depending on the position of the center of gravity of the load.
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13 Technical Data Axis data H600 H600 fast without with horstFX performance horstFX performance Axis Range Speed Speed movement (independent of load) (load capacity of 0 kg) +/- 173° 190°/s 370°/s +115° / -64° 70°/s 140°/s +41 / -176° 210°/s 420°/s +/- 172°...
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13 Technical Data horstCONTROL Rated power draw typ. 210 W (H600) Protection 6.3 A (2x) Communication TCP/IP 100 Mbit Ethernet (web interface / http) Safety-critical Emergency stop, safety stop, enabling switch interfaces +4 safe inputs, +6 safe outputs (2 relays) I/O connections on 20 inputs, +8 configurable horstCONTROL...
13 Stopping Distances and Stopping Times 13.2 Stopping Distances and Stopping Times The stopping distance is the distance covered by the TCP (Tool Center Point) after the stop signal is triggered and until a complete standstill is reached. DANGER! A speed update or load change can result in longer braking distances and unexpected colli- sions with people or other objects and machines.
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13 Stopping Distances and Stopping Times Fig. 13-2: Stopping distances of the main axes in degrees (°) with 3 kg The stopping distances and stopping times shown have been determined by trial and are intended as guide values. The actual stopping distances and stopping times may differ depending on operating mode, use case, and number of braking processes.
13 Optional Accessories 13.3 Optional Accessories The following accessories can be purchased from fruitcore robotics GmbH. Order no. Component Comment On request Tool flange On request Accessory flange plate On request Mobile Robot Base On request Safety laser scanner (270°)
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13 Optional Accessories Fig. 13-4: Mechanical stop, axis 3 Handling of Mechanical Stop, Axis 3: 1. In the software, set the stop to 10° or 20° 2. Loosen 2x cover screw 3. Assemble the stop assembly, tightening torque 2 Nm 4.
13 Spare Parts 13.4 Spare Parts The following spare parts can be purchased from fruitcore robotics GmbH. Order no. Component Comment On request Support arm 1 On request Support arm 2 On request Support arm 3 On request horstCONTROL On request...
13 Type Plates 13.5 Type Plates The robot’s type plate is located on the base of the rear side of the robot. Fig. 13-6: Robot type plate The horstCONTROL type plate is located on its rear side. Fig. 13-7: horstCONTROL type plate The horstPANEL type plate is located on its rear side.
13 Overview of Connectors 13.6 Overview of Connectors CONNECTOR DESCRIPTION Digital inputs 1-8 Digital inputs 9-16 Digital inputs 17-20, Enable (enabling switch) Test signals A / B Safe inputs 4-7 Emergency stop/safety stop Safe outputs 1-4 Safe outputs 5-6 (pot.free) Digital outputs 1-8 Digital outputs 9-16 Digital outputs 17-18, +24 V...
13 Terminal Assignment 13.7 Terminal Assignment Terminal Assignment Safe Description. X1.1 … X1.8 DI01 … DI08 General digital inputs 1-8 X2.1 … X2.8 DI09 … DI16 General digital inputs 9-16 X3.1 … X3.4 DI17 … DI18 General digital inputs 17-20 X3.5 Test signal for enabling switch, channel A X3.6...
13 Functional Wiring Diagrams of the Electrical Interfaces 13.8 Functional Wiring Diagrams of the Electrical Interfaces 13.8.1 horstCONTROL I/O Safe input Safe Output General digital input Potential-free output General digital output (High-Side)
14 Functional Wiring Diagrams of the Electrical Interfaces 14 Glossary Stop category 0 Stopping is achieved by an immediate interruption in the power supply to the drive components. This uncontrolled stopping can cause the robot to deviate from its programmed track. For more information on this, see EN ISO 13850 or DIN EN 60204-1.
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