Doosan A0509 Installation Manual
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Doosan A0509 Installation Manual

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Manual Version 1.8
Software Version 2.7.1
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Summary of Contents for Doosan A0509

  • Page 1 Manual Version 1.8 Software Version 2.7.1...

  • Page 2: Table Of Contents

    Preface ..............7 Copyright ........................7 Open Source Software License Information (OSS) ..........7 Safety ............8 1.1 Manual Indication Conventions ............... 8 1.2 Safety Symbols ....................9 1.3 General Instructions ..................10 1.4 Product Usage ....................12 1.5 Risk Assessment ....................13 1.6 Potential Risks ....................
  • Page 3 2.6 Nameplates and Labels ................... 40 Installation ..........41 3.1 Cautions during Installation ................41 3.2 Installation Environment ................. 42 Installation Location Check .......................................... 42 3.2.1 Robot Work Area Check ..........................................43 3.2.2 3.3 Hardware Installation ..................44 Securing the Robot ............................................... 44 3.3.1 Connecting the Robot and Tool ......................................
  • Page 4 6.2.2 6.3 Safety-Rated Monitoring Function ..............96 6.4 Safety-Rated I/O ....................98 Transportation .......... 99 7.1 Cautions during Transportation ..............99 7.2 Pose for Robot Transportation ..............100 7.3 Package Specifications ................. 101 Maintenance..........102 Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 5 10.3 Transfer ......................106 Indemnification ........107 Annex A System Specifications ....108 A.1 Manipulator ......................108 A.1.1 A0509(S) ....................................................108 A.1.2 A0912(S) ....................................................109 A.2 Controller ......................110 A.2.1 CS-01 (AC Controller) ............................................. 110 A.3 Emergency Stop Button .................. 111 A.3.1 CS-01 ......................................................
  • Page 6 C.1 Measurement Methods and Conditions ............125 C.1.1 General Information ..............................................125 C.1.2 Stop Category: ................................................. 126 C.1.3 Pose and condition for measurements: .................................... 127 C.2 A0509(S) ......................129 C.2.1 Stop Category 1 ................................................129 C.2.2 Stop Category 0 ................................................132 C.3 A0912(S) ......................133 C.3.1 Stop Category 1 ................................................

  • Page 7: Preface

    The copyright and intellectual property rights of the contents of this manual are held by Doosan Robotics. It is therefore prohibited to use, copy, or distribute the contents without written approval from Doosan Robotics. In the event of abuse or modification of the patent rights, the user will be solely responsible for the consequences.

  • Page 8: Safety

    Warning to the operator. Failure to observe instructions with this symbol may result in Caution product damage or cause injury to the operator. This is additional information to help the user. Note Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 9: Safety Symbols

    1.2 Safety Symbols Among the symbols used in this manual, symbols related to user safety are as follows: Symbol Description This symbol means that immediate hazards can occur due to electrical conditions such as high voltage. Failure to observe instructions with this symbol may result in serious accidents that could result in death or serious injury to the operator.

  • Page 10: General Instructions

    • To ensure user safety, joints may operate at a certain speed or higher, or the maximum speed of the TCP may be limited during direct teaching. If the limit is exceeded, the protective stop Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 11 function activates. • Enable/disable the direct teaching function when the robot has completely stopped. If the direct teaching function is enabled/disabled during robot operation, malfunctions may occur. • If the robot axis must be rotated when the robot is not operated, it can be rotated at a torque greater than 400 Nm.

  • Page 12: Product Usage

    The following uses are considered inappropriate because they exceed the boundaries of the product’s intended purpose. Doosan Robotics will not be held responsible for any damage and malfunctioning of the robot, property losses and injuries to users due to such inappropriate uses.

  • Page 13: Risk Assessment

    1.5 Risk Assessment One of the most important aspects of a system integrator is risk assessment. Risk assessment is legally mandatory in most countries. In addition, safety assessment of robot installation changes according to the overall system integration method, so it is impossible to perform risk assessment solely with the robot.
  • Page 14 (e.g., use of dangerous tool), the system integrator must decide to install additional protection devices during risk assessment (e.g., use of protection devices capable of protecting the integrator during installation and programming). Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 15: Potential Risks

    1.6 Potential Risks • Jamming fingers between the manipulator base and mount • Jamming limbs between the Link 1 and Link 2 (between Joint 3 (J3) and Joint 4 (J4)) • Jamming limbs between Joint 1 and Joint 2 (J1 and J2) and Joint 5 and Joint 6 (J5 and J6) •...

  • Page 16: Validity And Responsibility

    Indication of contact information or important notifications related to use and safety • Provision of technical documents including various manuals • Provision of information on standards and legislation applied: http://www.doosanrobotics.com/ Compliance with the safety requirements in this manual does not mean all risks can be prevented. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 17: Product Introduction

    Product Introduction 2.1 Component Check Manipulator (including connection cables)* Controller* Emergency Stop Button* Controller Power Cable Teach Pendant** Smart Pendant**...
  • Page 18 Components may vary depending on the robot model.  Items are indicated as standard items (*) and optional items (**, sold separately)  The laptop is not included in the package, and it is necessary when installing the DART Platform. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 19: Names And Functions

    2.2 Names and Functions 2.2.1 Manipulator Names of Parts  Name Name Base Link2 Link1 Tool flange...
  • Page 20 For more state, refer to the “5.4 LED (1-axis) information about robot State and Flange LED Color for Each Mode” Connector Used for supplying power to and communication of the robot. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 21: Controller

    2.2.2 Controller Item Description I/O connection terminal Used to connect the controller or peripherals. (internal) To use the Teach Pendant, Smart Pendant, or Emergency Emergency stop button Stop buttons, the switch must be set to match the actual setting switch configuration.

  • Page 22: Teach Pendant

    ※ The teach pendant is not a standard item but an optional item, so it must be purchased separately Note  If you need to protect and hold the Teach Pendant during work, you can use it more safely and easily with a soft cover supplied by Doosan Robotics. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 23: Smart Pendant

    2.2.4 Smart Pendant Item Description Used to indicate the robot’s state by displaying the same color as the Robot robot status LED to the user. Used to indicate whether the system entered smart pendant mode. Device LED Pressing four input signal buttons (F1-F4) lights the LED, indicating Function LED the press status.

  • Page 24: Emergency Stop Button

    2.2.5 Emergency Stop Button Item Description Emergency stop In case of an emergency, press the button to stop robot operation. button Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 25: System Configuration

    2.3 System Configuration Power Command/ Supply/ Monitoring Network Laptop Controller Manipulator ㅇ ㅇ ㅇ Command ㅇ Teach Pendant** Smart Pendant**/ Emergency Stop Button ㅇ • Laptop: After installing the DART Platform, a work environment identical to the teach pendant ㅇ can be set up.

  • Page 26: Product Specifications, General

    2.4 Product Specifications, General M-Series Technical Data A0509(S) refer to A.1.1 A0509(S) A0912(S) refer to A.1.2 A0912(S) Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 27: Robot Specifications

    < 65 dB Installation Direction Floor / Wall / Ceiling / Any Controller and Teaching Pendan Doosan Controller, DART Platform & Teach Pendant (Option) 10≤f< 57㎐ - 0.075 mm amplitude Vibration and Acceleration 57≤f≤150㎐ – 1G Max Amplitude : 50㎨ (5G) Impact * Time: 30 ㎳, Pulse: 3 of 3 (X,Y,Z)

  • Page 28: Axis Specifications

    ±360° ±360° ±360° ±360° Max. Speed per Axis (rated payload operation) 180 °/s 180 °/s 180 °/s 180 °/s 180 °/s 180 °/s 360 °/s 360 °/s 360 °/s 360 °/s 360 °/s 360 °/s Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 29: Robot Operating Space

    2.5.3 Robot operating space A0509 ...
  • Page 30 Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 31 A0509S ...
  • Page 32 Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 33 A0912 ...
  • Page 34 Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 35 A0912S ...
  • Page 36 Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 37: Max. Payload Within Operating Space

    2.5.4 Max. Payload within operating space The maximum payload of the robot within its operating space changes according to the distance from the center of gravity. Payload per distance is as follows: A0509  A0912 ...
  • Page 38 This load diagram assumes a small tool load volume. Tools with a larger volume will have greater limitations in payloads above the tool’s center of gravity compared to a tool with equal weight but smaller volume, and in such cases, vibration may occur. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 39: Tool Center Point (Tcp)

    2.5.5 Tool Center Point (TCP) Refer to the figure below for TCP.

  • Page 40: Nameplates And Labels

    2.6 Nameplates and Labels Be careful not to remove or damage labels attached to the robot and controller. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 41: Installation

    Installation 3.1 Cautions during Installation Warning • Secure sufficient space for installation before installing the robot. If not enough space is secured, the robot may be damaged or the user may be injured. • Safety devices to be connected to the controller must be connected to a safety contact input terminal or a configurable digital I/O set as Safety I/O using dual signals.

  • Page 42: Installation Environment

    Install the robot in a location with no water leakage and with constant temperature and humidity. • Check whether flammable and explosive materials are near the installation location. Caution • Installing the robot in locations other than the recommended locations may result in reduced robot performance and product life. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 43: Robot Work Area Check

    3.2.2 Robot Work Area Check Secure installation space considering the operating space of the robot. The operating space varies according to the robot model. Note  The gray areas in the figure are areas where the robot has difficulty performing work. Within this area, the speed of tools is low but the speed of joints is high, making it difficult to conduct a risk assessment because the robot can operate inefficiently.

  • Page 44: Hardware Installation

    And use a washer(plain or spring) to prevent loosening of the tension caused by vibration. • Use a Φ5 place marker pin to accurately install the manipulator in a fixed location. manipulator base drawing, use four M8 bolts. Unit [mm] Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 45 Warning  Tighten the bolts all the way to prevent loosening during manipulator operation.  Install the manipulator base on a solid surface that can withstand the load generated during operation (10 times the maximum torque and five times the weight of the robot). ...

  • Page 46: Connecting The Robot And Tool

    Connect the necessary cables to the tool I/O after the tool is secured. Note Methods of securing the tool may vary according to the tool. For more information about tool installation, refer to the manual provided by the tool manufacturer. Tool output flange, ISO 9409-1-50-4-M6 Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 47: Connecting The Manipulator And Controller

    3.3.3 Connecting the Manipulator and Controller Push the manipulator cable connected to the robot into the corresponding controller connector until a click is heard to prevent the cable from becoming loose. Connect the robot cable to the controller Caution  Do not disconnect the manipulator cable when the robot is turned on.
  • Page 48  If the controller is affected by the noise generated by electromagnetic waves, it is necessary to install a ferrite core to ensure normal operation. The installation location is as follows: Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 49: Connecting The Controller And Emergency Stop Button

    3.3.4 Connecting the Controller and Emergency Stop Button Connect the emergency stop button cable to the corresponding controller connector and install a screw lock by turning it clockwise to prevent the cable from becoming loose. Connect the emergency stop button cable to the controller Warning If the setting(Section 3.3.10 Emergency Stop Button Setting Switch) of the emergency stop ...

  • Page 50: Connecting The Controller, And Smart Pendant

    Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 51 Caution  Make sure to check that the pins of the cable end are not damaged or bent before connecting the cable.  If the smart pendant is used by hanging it on the wall or on the controller, be careful not to trip on the connecting cables.

  • Page 52: Connecting The Controller And Teach Pendant

    Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 53 Caution  Make sure to check that the pins of the cable end are not damaged or bent before connecting the cable.  If the teach pendant is used by hanging it on the wall or on the controller, be careful not to trip on the connecting cables.

  • Page 54: Routing Of Cables

    Ensure that the cable curvatures are greater than the minimum curvature radius. The minimum curvature radius of each cable is as follows: Cable Minimum Curvature Radius (R) Teach pendant cable 120 mm Robot cable 120 mm Smart pendant cable 100 mm Emergency stop button cable 100 mm Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 55: Supplying Power To The Controller

    3.3.8 Supplying Power to the Controller To supply power to the controller, connect the power cable of the controller to a standard IEC power outlet. • Use a cable with a standard power plug that matches the outlet of country of use. •...

  • Page 56: System Power-Up

    3.3.9 System Power-Up Press the power button located on the bottom of the controller. • Power is supplied to systems including the robot, controller, teach pendant and smart pendant. Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 57 [PC Power ON/OFF when only E-STOP Box is available - Standard Item] Open the controller door, and press and hold the power button located below the bottom right of the Safety board. • To turn off the power, press and hold the button. ON/OFF Switch ON/OFF Switch...
  • Page 58 Press and hold the power button located on the top left of the smart pendant. • To turn off the power, press and hold the button. Note  If a system does not power up, check the power switch located on the bottom of the controller. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 59: Emergency Stop Button Setting Switch

    3.3.10 Emergency Stop Button Setting Switch Configure the emergency stop button setting switch on the Case according to components and additional components before connecting and starting up the product. If the setting is not configured according to the guide, the robot will not operate properly. The emergency stop button setting switch is located on the bottom left of the board inside the controller door (refer to below).

  • Page 60: Interface

    ▪ Phoenix contact 1404182, male (Right Angle) The pin map of each connector is as follows: Schematic Diagram  The I/O functions provided through X1 connector are different from each other, and refer to the table below for detailed I/O settings. Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 61 Configure tools and grippers after checking I/O configuration based on production date (robot label mfg date).  You can find it on Doosan Robotlab.(https://robotlab .doosanrobotics.com)  If you run robot tools ignoring I/O configuration, the product can be damaged permanently.
  • Page 62 The No. 5 terminal of each connector outputs 24V at all times while power is supplied to the robot, so make sure to cut the power supply to the robot when setting up the tool and gripper. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 63: Flange Digital Output Specifications

    4.1.1 Flange Digital Output Specifications Flange digital output is a PNP specification, and photo coupler output is set up in the output. The corresponding output channel becomes +24V when digital output is activated. The corresponding output channel is open (floating) when digital output is deactivated. The electrical specifications of the digital output are as follows: Parameter Unit...

  • Page 64: Flange Digital Input Specifications

    The figure below is an example of a digital input setup, so refer to it while connecting an input device. Make sure to disconnect the power from the robot when setting up the circuit. +24V Flange Interface Board 4.4K Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 65: Controller I/O Connection

    Turn off the power when connecting terminals to the controller I/O to prevent product damage and breakdown.  Doosan Robotics will not compensate any product damage caused by inappropriate terminal connection or user negligence.  Make sure to turn off the external power source when turning off the controller power.

  • Page 66: Setting The Terminal Block For Contact Input (Tbsft)

    If any of the contacts are open, the robot will stop operation according to the safety stop mode setting, and the LED on the right side of the TBSFT lights up. EMGA (Red), EMGB (Red), PRDA (Yellow), PRDB (Yellow) Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 67 Note  EMGA : Emergency Stop channel A(EM1) LED  EMGB : Emergency Stop channel B(EM2) LED  PRDA : Protective Stop channel A(PR1) LED PRDB : Protective Stop channel B(PR2) LED  Caution  To check for connection losses and connection shortages, this terminal must be connected to devices that output a safety signal as contacts.

  • Page 68: Setting The Digital I/O Power Terminal (Tbpwr)

    SMPS.  If a current greater than 2A is required for the configurable digital I/O, make sure to connect an external power source (24V) to VIO and GIO. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 69: Setting The Configurable Digital I/O (Tbci1 - 4,Tbco1 - 4)

    4.2.3 Setting the Configurable Digital I/O (TBCI1 - 4,TBCO1 - 4) The digital I/O of the controller consists of 16 inputs and 16 outputs. They are used to connect peripherals required for robot control or are set as a dual safety I/O to be used as safety signal I/O purposes.
  • Page 70 Safety Controller Wet Contact Connection (Voltage/Current from Ext. Source) Board VIO (24V) TBCI1~TBCI4 I01~I16 PNP output Pushbutton (Source type) / Switch Common Ground NPN output (Sink type) with Relay Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 71 • If a simple load is operated This is a method of connecting loads between the O01-O16 terminals of the TBCO1-TBCO4 terminal blocks and the GIO terminal. Each terminal is capable of outputting a maximum of 1A, but the overall current may be limited according to the calorific value and load.
  • Page 72 TBCO4 terminal blocks to the input terminal of the external device, and connect the GIO to the negative common of the external device to establish a common ground. FUSE 2A TBPWR SMPS Digital Isolator Negative common O01~O16 & Sink type input Logic Voltage Source Output TBCO1~TBCO4 Common Ground COM(N) Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 73 • If a positive common & source type input device is connected Connect a relay between the Oxx terminal of TBCO1-TBCO4 terminal blocks and GIO terminal to supply input signals as contacts to the external device. If necessary, an external power supply can be connected to the external device.
  • Page 74 The following is an example of connecting a safety device for operation. • Connecting an emergency switch (contact signal) as a safety input terminal • Connecting a light curtain (voltage signal) as a safety input terminal (common ground) Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 75: Setting Analog I/O Terminal (Tbaio)

    4.2.4 Setting Analog I/O Terminal (TBAIO) The controller features two analog I/O terminals that can be set to voltage mode or current mode. It can output voltage/current through an external device operated using analog I/O or receive signals from sensors outputting analog voltage/current. To ensure maximum input accuracy, observe the following: •...
  • Page 76 “Voltage” or “Current” on the teach pendant. Safety Controller Board 4 -20 mA 0 - 10 Vdc AO1~2 4 - 20 mA Field Input IOUT TBAIO Ex)PLC, DCS, Actuator Voltage & Current VOUT Combined 0 - 10 Vdc Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 77: Setting Encoder Input Terminal (Tben1, Tben2)

    4.2.5 Setting Encoder Input Terminal (TBEN1, TBEN2) The controller has two TBEN terminals that allow the input of external encoders. They support A, B and Z phases as inputs, and perform counts based on 12Vdc. In addition, S phase can be used as the conveyor’s Start sensor. The figure below shows a sample encoder and sensor configuration, so refer to it while establishing connections.
  • Page 78 • In the case of S phase inputs, connect a pull-up or pull-down resistance according to the sensor type(NPN/PNP) to prevent floating. • Connecting NPN Sensor • Connecting PNP Sensor Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 79: Network Connection

    4.3 Network Connection Laptops, TCP/IP equipment, Modbus equipment and vision sensors can be connected to the network connector terminal inside the controller. Connecting the cable to the network connection terminal will connect the network (refer to the figure below). 4.3.1 Connecting External Devices - Vision Sensor The robot can be connected with a vision sensor (2D camera for object position measurement), and vision sensor measurements can be transferred to the robot through a network to link with commands of the...
  • Page 80 The Doosan Robot Language (DRL) enables the connection, communication and control of the external vision sensor, and it is possible to set up the program in Task Writer.

  • Page 81: Connecting External Device - Dart Platform

    Connecting External Device – DART Platform 4.3.2 The DART Platform is software that runs on a Windows OS base desktop or laptop. Once you execute the DART Platform after connecting the controller and desktop/laptop through the LAN Port, all functions of the teach pendant can be used without a teach pendant.

  • Page 82: Modbustcp Slave Setup

    4.3.3 ModbusTCP Slave Setup The ModbusTCP Slave function of Doosan Robotics supports robot parameter monitoring, General Purpose Register (GPR) (refer to 4.3.7 Using General Purpose Register (GPR)) function.This function starts automatically when the robot controller boots up normally. Therefore, the user can use it after matching the Master IP of the robot controller with the same bandwidth.

  • Page 83: Expanded Protocol - Profinet Io Device (Pnio Device) Setup

    4.3.4 Expanded Protocol - PROFINET IO Device (PNIO device) Setup The robot controllers of Doosan Robotics support the PROFITNET IO Device (Slave) function, which allows data modification after reading the Parameters of the robot from an external device (PROFINET IO Controller/Master ).

  • Page 84: Expanded Protocol - Ethernet/Ip Adapter (Eip Adapter) Setup

    4.3.5 Expanded Protocol - EtherNet/IP Adapter (EIP adapter) Setup The robot controllers of Doosan Robotics support the EtherNet/IP Adapter (Slave) function, which allows data modification after reading the Parameters of the robot from an external device (EtherNet/IP Scanner / Master). ( e.g., Robot parameter monitoring, General Purpose Register (Bit, Int, Float) – refer to 4.3.7 Using General Purpose Register (GPR)).

  • Page 85: Using Expanded Protocol

    The following are descriptions of implementation characteristics of general functions for Industrial Ethernet.  The Industrial Ethernet function of Doosan Robotics controllers does not use a separate ASIC, but implements its function based on TCP/IP, so it does not support real-time performance. ...

  • Page 86: Using General Purpose Register (Gpr)

    The GPR function is only provided through DRL, and the DRLs used are as follows: For more information about DRL, please refer to the Programming Manual.  set_output_register_bit(address, val)  set_output_register_int(address, val)  set_output_register_float(address, val)  get_output_register_bit(address)  get_output_register_int(address)  get_output_register_float(address)  get_input_register_bit(address)  get_input_register_int(address)  get_input_register_float(address) Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 87: Robot Mode And State

    Robot Mode and State The operation modes of the robot consist of Manual Mode, where the user controls the robot directly, and Automatic mode, where the robot operates without direct user control. 5.1 Manual Mode This is the mode in which the robot operates according to direct user control. The robot only operates when a button related to an action is pressed, and releasing the button results in stopping the corresponding action.

  • Page 88: Automatic Mode

    Enable Switch can be connected through the I/O by the setting in the WCM > Robot > Safety I/O. In this case, the Enable Switch must be placed in the center-enable position to allow Play or Start, Resume and Servo On in Automatic Mode. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 89: Other Mode

    Other Mode Unlike normal modes such as manual mode and automatic mode, this is exceptional mode. This mode includes special states such as controller booting, initializing and states related to Backdrive at which you can push robot by hand without drive power..

  • Page 90: State And Flange Led Color For Each Mode

     The robot pose can be changed by pressing the "Handguiding" button. HGC Running Cyan Blinking  After the robot stops, enter HGC End & Resume signal through the Safety IO to set Auto Running and then Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 91 Flange and/or Mode State Description Base LED continue executing the task program.  The weight and center of gravity point of the end effector are measured automatically. Please note that the safety Yellow Auto-measure monitoring functions of the robot are disabled during auto- Blinking measuring.

  • Page 92: Safety Functions

    Safety Functions 6.1 Introduction Robot’s from Doosan Robotics use various safety-rated monitoring and safety-related electrical interfaces to protect users and devices, and it allows the integration of other devices and additional protection devices. The performance of each safety-rated monitoring function and interface satisfies Category 3, Performance Level d(PL d) defined by ISO 13849-1 and Hardware Fault Tolerance 1, Safety Integrity Level 2 (SIL 2) defined by IEC 62061.

  • Page 93: Safety-Rated Stop Function

    6.2 Safety-Rated Stop Function This is the stop function and stop monitoring function of Doosan Robotics, and it uses the safety function defined in IEC 61800-5-2. Safety Function Function Description and Failure Detection PFHd PL, SIL Name Immediately cuts off the power supply to all joint module motors, and 2.64E-8...

  • Page 94: Emergency Stop Function

    Emergency stop must not be used as a risk reduction method, but as a secondary protection device.  If additional emergency stop buttons need to be connected, this must be determined with a robot application risk assessment. The Emergency Stop button must comply with IEC 60947-5- Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 95: Protective Stop

    6.2.2 Protective Stop The robot features a protective stop function to stop the robot according to signals sent by protective devices. For information about the protective device connection, refer to sections 4.2.1 Setting the Terminal Block for Contact Input (TBSFT) and 4.2.3 Setting the Configurable Digital I/O (TBCI1 - 4,TBCO1 - 4).

  • Page 96: Safety-Rated Monitoring Function

    6.3 Safety-Rated Monitoring Function Doosan robot’s feature various safety-rated monitoring functions that can be used as a risk reduction measure through risk assessment. The threshold of each monitoring function that triggers stop can be configured in the WCM>Robot>Robot Limit of the teach pendant UI.
  • Page 97 Safety Stop Function Stop Triggering Event PFHd PL, SIL Mode Name Robot STO, PL d Cat. If the momentum of the robot exceeds the configured 3.90E-7 Momentum SS1 or threshold Limit SIL 2 STO, PL d Cat. Robot If the mechanical power of the robot exceeds the 3.90E-7...

  • Page 98: Safety-Rated I/O

    6.4 Safety-Rated I/O robot’s of Doosan Robotics feature a safety-rated input interface capable of connecting protective stop signals from safety protective devices, external emergency stop signal input and 3-position Enable Switch. They also feature a safety-rated output interface capable of outputting internal status and area information.

  • Page 99: Transportation

    When transporting the robot using lifting equipment, make sure to observe all related national and regional regulations. • Doosan Robotics does not assume responsibility for any damages or losses that occur during transportation, so make sure to transport the robot safely according to the user manual.

  • Page 100: Pose For Robot Transportation

    7.2 Pose for Robot Transportation Set the following poses to transport the robot: Model A0509(S) -180° 0° 150° 0° 25° 0° A0912(S) -180° 0° 160° 0° 20° 0° Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 101: Package Specifications

    7.3 Package Specifications The box specifications for transport are as follows: Model Length Width Height 450 mm 545 mm A0509(S) 755 mm 986 mm 452 mm 545 mm A0912(S)

  • Page 102: Maintenance

    Maintenance System maintenance must be performed by Doosan Robotics or a company designated by Doosan Robotics. Maintenance covers maintaining system operability and recovering system operability in the event of an issue, and it includes repair work and system diagnosis of potential issues.

  • Page 103: Disposal And Environment

    Therefore, do not dispose of the system along with general industrial or home waste. When disposing of all or part of the system, the relevant laws and legislation must be complied with, and contact Doosan Robotics for detailed information related to the disposal of the system.

  • Page 104: Product Warranty And Responsibility

    The only responsibility the Manufacturer offers and the only measure the Customer can receive in terms of Doosan Products within the scope of this warranty is restricted to repairing or replacing Doosan Products with defects. Doosan does not compensate any or all financial, operation or productions losses, any or all indirect losses such as damage to other equipment, and any or all deliberate, special or consequential losses that occur due to defects of Doosan Products.

  • Page 105: Restrictions And Exceptions Of Warranty

    • If parts or S/W not provided by Doosan are installed • If a Doosan Product is incorrectly repaired or maintained by an unofficial repair technician or unauthorized individuals • If the user has modified a Doosan Product without prior approval from the Manufacturer •...

  • Page 106: Transfer

    10.3 Transfer This warranty is included in the warranty period, and if a Doosan robot is sold to a different individual through a private transaction, the warranty can also be transferred. However, the warranty is only valid if the Manufacturer is notified of such a transaction, and the warranty period is still in effect. The assignee of this warranty must observe all conditions stipulated in this warranty.

  • Page 107: Indemnification

    Indemnification Doosan Robotics continues to upgrade its product reliability and performance, and has the right to upgrade the product without notification. Doosan Robotics endeavors to ensure that all contents in this manual are accurate. However, it does not assume responsibility for errors or missing information.

  • Page 108: Annex A System Specifications

    Classification Item Specifications Axis Structure Payload 5 kg Performance Max. Radius A0509 : 900 mm / A0509S : 903 mm TCP Speed Over 1m/s Repeatability ± 0.03mm J1 Range / Speed ±360° / 180°/s J2 Range / Speed ±360° / 180°/s J3 Range / Speed ±160°...

  • Page 109: A0912(S)

    A.1.2 A0912(S) Classification Item Specifications Axis Structure Payload 9 kg Performance Max. Radius A0912 : 1200 mm / A0912S : 1203 mm TCP Speed Over 1m/s Repeatability ± 0.05mm J1 Range / Speed ±360° / 180°/s J2 Range / Speed ±360°...

  • Page 110: Controller

    Ethernet / USB / RS-232 I/O Port – Digital I/O 16/16 I/O Port – Analog I/O I/O power supply DC24V ModbusTCP Master/Slave, ModbusRTU Master, Industrial Network PROFINET IO Device, EtherNet/IP Adapter Rated supply voltage 100-240VAC 47-63 Hz Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 111: Emergency Stop Button

    A.3 Emergency Stop Button A.3.1 CS-01 Item Specifications Weight 0.2 kg Dimensions 68 x 91.5 x 68 mm Protection Rating IP 65...

  • Page 112: Smart Pendant (Option)

    A.4 Smart Pendant (Option) A.4.1 CS-01 Item Specifications Weight 0.3 kg Dimensions 180 x 90 x 26.5 mm Protection Rating IP 40 Cable Length Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 113: Teach Pendant (Option)

    A.5 Teach Pendant (Option) A.5.1 TP-01 Item Specifications Weight 0.8 kg Dimensions 264 x 218 x 42 mm Protection Rating IP 30 Screen Size 10.1 inches i Cable Length 4.5 m...

  • Page 114: Fts (A0509S, A0912S Only)

    Overload Capacity 150%L.C.(Load Capacity) 16.5 Nm 16.5 Nm 16.5 Nm Data Rate 1000 Hz Operating Temperature 0 - 45 °C (273K-318K) Caution Make sure to use Quick Guide provided by Doosan Robotics as a referrence.  Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 115: Dart Platform Installation Requirement (Minimum, Recommended)

    A.7 DART Platform Installation Requirement (minimum, recommended) The minimum installation requirements for the DART Platform are as follows: • OS: Windows 7 Enterprise Service pack1 (64 bit) or higher • CPU: 2.20 GHz or higher • GPU: GMA 4500 and GMA HD (Intel) or equivalent specification •...

  • Page 116: Annex B Declaration And Certification

    Annex B Declaration and Certification B.1 Europe Declaration of Incorporation (Original) Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 117: Europe Machinery Directive Attestation Of Conformity

    B.2 Europe Machinery Directive Attestation of Conformity...

  • Page 118: Europe Emc Directive Attestation Of Conformity

    B.3 Europe EMC Directive Attestation of Conformity Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 119: U.s. Nrtl Certification (U.s., Canada)

    B.4 U.S. NRTL Certification (U.S., CANADA)
  • Page 120 Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 121: Voluntary Safety Confirmation Declaration (Kcs)

    B.5 Voluntary Safety Confirmation Declaration (KCs)
  • Page 122 Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 124 Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 125: Annex C Stop Distance And Stop Time

    Annex C Stop Distance and Stop Time C.1 Measurement Methods and Conditions C.1.1 General Information ⚫ Stop distance is the angle traveled from the moment a stop signal is generated to the moment all manipulator stop operation. ⚫ Stop time is the time from the moment a stop signal is generated to the moment all manipulator stop operation.

  • Page 126: Stop Category

    Joint 1 measurement is performed with the rotating axis perpendicular to the ground and during horizontal movement. Joint 2 and Joint 3 measurements are performed with the rotating axis parallel to the ground and when the robot is stopped in a downward movement vertical to the ground. Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 127: Pose And Condition For Measurements

    C.1.3 Pose and condition for measurements: Joint 1 Joint 2 Joint 3 100% extension Stop category 0 33% extension Stop category 1 66% extension Stop category 1 100% extension Stop category 1 Table C.1 the pose for 33%, 66%, and 100% of extension...
  • Page 128 No slip, �� Joint1 = �� �� ��1 Stop initiating position �� Joint2 ��2 �� �� ��3 Stop initiating position Joint3 Table C.2 the pose when the stop is initiated and the measured angle (�� �� Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 129: A0509(S)

    C.2 A0509(S) C.2.1 Stop Category 1 (a) Stop Distance at 33% of Max. Load (rad) (d) Stop Time at 33% of Max. Load (ms) (b) Stop Distance at 66% of Max. Load (rad) (e) Stop Time at 66% of Max. Load (ms) (c) Stop Distance at Max.
  • Page 130 (b) Stop Distance at 66% of Max. Load (rad) (e) Stop Time at 66% of Max. Load (ms) (c) Stop Distance at Max. Load (rad) (f) Stop Time at Max. Load (ms) Figure C.2: Stop Distance and Stop Time of Joint 2 (Shoulder) Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 131 (a) Stop Distance at Max. Stretch Level (rad) (b) Stop Time at Max. stretch Level (ms) Figure C.3: Stop Distance and Stop Time of Joint 3 (Elbow)

  • Page 132: Stop Category 0

    Joint 2 (�� 0.005 ��2 Joint 3 (�� 0.163 ��3 Distance (�� 0.167 ���� ※ The joint 2 and joint 3 angles are refer to �� , �� , �� in table C.2 ��2 ��3 �� Doosan Robotics Installation(A-Series) Manual v1.8...

  • Page 133: A0912(S)

    C.3 A0912(S) C.3.1 Stop Category 1 (a) Stop Distance at 33% of Max. Load (rad) (d) Stop Time at 33% of Max. Load (ms) (b) Stop Distance at 66% of Max. Load (rad) (e) Stop Time at 66% of Max. Load (ms) (c) Stop Distance at Max.
  • Page 134 (b) Stop Distance at 66% of Max. Load (rad) (e) Stop Time at 66% of Max. Load (ms) (c) Stop Distance at Max. Load (rad) (f) Stop Time at Max. Load (ms) Figure C.5: Stop Distance and Stop Time of Joint 2 (Shoulder) Doosan Robotics Installation(A-Series) Manual v1.8...
  • Page 135 (a) Stop Distance at Max. Stretch Level (rad) (b) Stop Time at Max. stretch Level (ms) Figure C.6: Stop Distance and Stop Time of Joint 3 (Elbow)
  • Page 136 Joint 2 (�� 0.018 ��2 Joint 3 (�� 0.318 ��3 Distance (�� 0.329 ���� The joint 2 and joint 3 angles are refer to �� , �� , �� in table C.2 ��2 ��3 �� Doosan Robotics Installation(A-Series) Manual v1.8...

This manual is also suitable for:

A0509sA0912A0912s

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