3. Installation

3.1. Instructions for security

3.1.1. Brief introduction

This manual will use the following warnings. The role of these warnings is to ensure the safety of personal and equipment. When you read this manual, you must comply with and execute all the assembly instructions and guidelines in other chapters in this manual. This is very important. Pay special attention to text related to warning signs.

Important

  • If the robot (robot body, control box, teaching pendant, or button box) is damaged, changed or modified due to anthropogenic causes, FAIR INNOVATION refuses to bear all responsibilities;

  • FAIR INNOVATION is not responsible for any damage caused by the robot or any other device due to errors written by customers or any other device.

3.1.2. Personnel safety

When running the robot system, we must first ensure the safety of the operators. The general precautions are listed below. Please take corresponding measures to ensure the safety of the operator.

  1. All operators who use the robot system should be trained through training courses sponsored by the FAIR INNOVATION (Suzhou) ROBOTIC SYSTEM COMPANY. Users need to ensure that they fully grasp the safe and standardized operating processes and have the qualifications for robotic operations. For training details, please check with our company, the mailbox is jiling@frtech.fr.

  2. All operators who use the robot system, please do not wear loose clothes or jewelry. Make sure the long hair beam is behind the head when operating the robot.

  3. During the operation of the device, even if the robot seems to have stopped, it may be because the robot is waiting to start the signal and is in a state of motion. Even in such a state, the robot should be regarded as in action.

  4. The lines should be drawn on the floor to mark the scope of the robot, so that the operator understands the action range of the robot includes holding tools (robotics, tools, etc.).

  5. Ensure safety measures (such as guardrails, ropes, or protective screens) near the robotic operation area to protect operators and surrounding people. Locks should be set up as needed, so that those who are responsible for operations cannot reach the power supply of the robot.

  6. When using the operating panel and teaching pendant, because you may have an operational error in wearing gloves, you must work after taking off the gloves.

  7. Under the emergency and abnormalities of people being pinched or wrapped inside by a robot, pushing or pulling the robot arm by force (at least 700 N) to force joint movements. With a power-free driver, the arm of the manual mobile robot is limited to emergency and may damage the joint.

3.1.3. Danger recognition

Risk assessment should consider all potential contact between operators and robots during normal use and foreseeable misunderstandings. The operator’s neck, face, and head should not be exposed to avoid touch. Using robots without using peripheral safety protection devices requires the first risk assessment to determine whether the relevant hazards will constitute an unacceptable risk, such as

  • There may be danger of using a sharp end actuator or tool connector;

  • There may be danger of treatment of toxicity or other harmful substances;

  • The operator’s finger has the danger of being clamped by a robot base or joint;

  • The danger of collision by robots;

  • The danger of robots or tools connected to the end not being fixed in place;

  • The risk of the impact between the effective load and the strong surface of the robot.

Integrates must measure such dangers and related risk levels through risk assessment, and determine and implement corresponding measures to reduce the risk to acceptable levels. Please note that there may be other major dangers in specific robots.

By combining the inherent security design measures used by FR robots with the safety specifications or risk assessment implemented by integrated and end users, the risks related to FR collaborative operations will be reduced to a reasonable and feasible level. Through this document, any remaining risk of the robot can be conveyed to the integrated and end users before installation. If the risk assessment of the integrator determines that the existence of a specific application that may have unacceptable risks that may constitute unacceptable risks, integrators must appropriate risk reduction measures must be taken to eliminate or minimize these dangers until the risk is reduced to acceptable levels. It is not safe to use before taking appropriate risk reduction measures (if necessary).

If the robot is installed in non-synergistic installation (for example, when using a hazardous tool), risk assessment may infer the integrated provider to connect additional safety equipment (such as safety startup equipment) to ensure personnel and equipment safety when programming.

3.1.4. Nameplate information

../_images/0026.png

Figure 3.1-1 FR3 model collaborative robot

../_images/1062.png

Figure 3.1-2 FR3-WMS model collaborative robot

../_images/1072.png

Figure 3.1-3 FR3-WML model collaborative robot

../_images/1082.png

Figure 3.1-4 FR3-C model collaborative robot

../_images/0037.png

Figure 3.1-5 FR5 model collaborative robot

../_images/1282.png

Figure 3.1-6 FR5-C Model Collaborative Robot

../_images/1262.png

Figure 3.1-7 FR5-WML model collaborative robot

../_images/0047.png

Figure 3.1-8 FR10 model collaborative robot

../_images/0057.png

Figure 3.1-9 FR16 model collaborative robot

../_images/0067.png

Figure 3.1-10 FR20 model collaborative robot

../_images/0076.png

Figure 3.1-11 FR30 model collaborative robot

../_images/1252.png

Figure 3.1-12 FR30L model collaborative robot

3.1.5. Effectiveness and responsibility

The information in this manual does not include a complete robot application in design, installation and operation, nor does it contain all peripheral equipment that may affect the security of this complete system. The design and installation of this complete system must meet the safety requirements established in the standards and specifications of the country’s installation.

The integrated integrator of FAIR INNOVATION is responsible for ensuring that it follows the laws and regulations of relevant countries, and there is no major danger in the complete robotic application. This includes but not limited to the following:

  • Do a risk assessment of the complete robot system

  • Connect other machinery and additional safety equipment defined by risk assessment and definition

  • Establish appropriate security settings in software

  • Make sure that users will not modify any security measures

  • Confirm that the design and installation of the entire robot system is accurate

  • Clear instructions for use

  • Kark the relevant signs and contact information of integrators on the robot

  • Collect all the documents in the technical file, including this manual

3.1.6. Limited responsibility

Any security information contained in this manual shall not be regarded as a general robot safety guarantee. Even if you comply with all security descriptions, it may still cause personnel damage or equipment damage.

3.1.7. The warning signs in this manual

The following flag defines the explanation of the danger level provisions contained in this manual. The product also uses the same warning signs.

Important

../_images/0085.png

Danger: This refers to the power consumption that is about to cause danger. If it is not avoided, it can lead to death or severe damage.

Important

../_images/0094.png

Electric shock danger: This refers to the upcoming electric shock situation that is about to cause danger.

Important

../_images/0105.png

Dangerous burns: This refers to the hot surface that may cause danger. If you do not avoid contact, it can cause personnel to hurt.

3.1.8. Pre-use evaluation

After using a robot or any modification for the first time, the robot’s default speed is less than 250mm/s. Do not log in to the administrator to modify the speed to enter the high-speed mode. After that, the following test must be performed. It is confirmed that all security input and output are correct and the connection is correct. Test whether all connected security input and output (including multiple machines or robots shared equipments) are normal. So you must:

  • Test whether the emergency stop button and input can stop the robot and start the brake.

  • Test whether the protection input can stop the robot movement. If the protection reset is configured, check if you need activation before recovery.

  • The test operation mode can switch the operation mode, see the icon in the upper right corner of the user interface.

  • Test whether the 3rd gear actuation device must be pressed to activate in manual mode, and the robot is under deceleration control (the robot software version V3.0 does not support this function).

  • Test whether the system emergency stop output can bring the entire system to a safe state.

3.1.9. Emergency stop

The emergency stop button is type 0 stop. Press the emergency stop button to stop all the movements of the robot immediately.

The following table shows the stop distance and stop time of the type 0 stop. These measurement results correspond to the following configuration of the robot:

  • Extension: 100%(the robotic arm is fully expanded)

  • Speed: 100%(Robot general speed is set to 100%, moved at a joint speed of 180 °/s)

  • Effective load: Maximum effective load

Joint 1, joint 6 testing robot levels, the rotating shaft is perpendicular to the ground. Joint 2, joint 3, joint 4, joint 5 testing robots follow the vertical trajectory, the rotating shaft is parallel to the ground, and stops when the robot moves down.

Table 3.1-1 Category 0 stop distance(rad)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

0.47

0.60

0.56

0.29

0.10

0.06

FR3-WMS

0.47

0.60

0.56

0.29

0.10

0.06

FR3-WML

0.51

0.63

0.60

0.33

0.16

0.10

FR3-C

0.47

0.60

0.56

0.29

0.10

0.06

FR5

0.51

0.63

0.60

0.33

0.16

0.10

FR5-C

0.51

0.63

0.60

0.33

0.16

0.10

FR10

0.64

0.70

0.69

0.42

0.25

0.13

FR16

0.60

0.67

0.65

0.39

0.22

0.12

FR20

0.69

0.75

0.80

0.48

0.31

0.22

FR30L

0.69

0.75

0.80

0.48

0.31

0.22

Table 3.1-2 Category 0 stop time (ms)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

400

470

450

280

120

90

FR3-WMS

400

470

450

280

120

90

FR3-WML

400

470

450

280

120

90

FR3-C

400

470

450

280

120

90

FR5

420

500

480

310

150

120

FR5-C

420

500

480

310

150

120

FR10

460

540

510

330

170

140

FR16

440

530

490

320

160

130

FR20

540

600

700

400

260

170

FR30L

540

600

700

400

260

170

After the emergency stop, turn off the power, rotate the emergency stop button, and turn on the power to restart the robot.

At the same time, the stop time and stop distance of the robot safety stop and soft limit stop are shown in the table below. These measurement results correspond to the following configuration of the robot:

  • Extension: 100%(the robotic arm is fully expanded)

  • Speed: 100%(Robot general speed is set to 100%, moved at a joint speed of 180 °/s)

  • Effective load: Maximum effective load

Joint 1, joint 6 testing robot levels, the rotating shaft is perpendicular to the ground. Joint 2, joint 3, joint 4, joint 5 testing robots follow the vertical trajectory, the rotating shaft is parallel to the ground, and stops when the robot moves down.

Table 3.1-3 Safety stop distance(rad)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

0.49

0.63

0.58

0.32

0.12

0.09

FR3-WMS

0.49

0.63

0.58

0.32

0.12

0.09

FR3-WML

0.54

0.65

0.63

0.35

0.19

0.12

FR3-C

0.49

0.63

0.58

0.32

0.12

0.09

FR5

0.54

0.65

0.63

0.35

0.19

0.12

FR5-C

0.54

0.65

0.63

0.35

0.19

0.12

FR10

0.66

0.73

0.71

0.45

0.27

0.14

FR16

0.63

0.69

0.68

0.41

0.25

0.14

FR20

0.71

0.78

0.82

0.51

0.33

0.25

FR30L

0.71

0.78

0.82

0.51

0.33

0.25

Table 3.1-4 Safety stop time(ms)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

410

490

410

300

130

110

FR3-WMS

410

490

410

300

130

110

FR3-WML

410

490

410

300

130

110

FR3-C

410

490

410

300

130

110

FR5

450

520

510

330

180

140

FR5-C

450

520

510

330

180

140

FR10

480

570

530

360

190

170

FR16

470

550

520

340

190

150

FR20

560

630

720

430

280

200

FR30L

560

630

720

430

280

200

Table 3.1-5 Soft limit stop distance(rad)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

0.52

0.65

0.61

0.34

0.15

0.11

FR3-WMS

0.52

0.65

0.61

0.34

0.15

0.11

FR3-WML

0.56

0.68

0.65

0.38

0.21

0.15

FR3-C

0.52

0.65

0.61

0.34

0.15

0.11

FR5

0.56

0.68

0.65

0.38

0.21

0.15

FR5-C

0.56

0.68

0.65

0.38

0.21

0.15

FR10

0.69

0.75

0.74

0.47

0.30

0.18

FR16

0.65

0.72

0.70

0.44

0.27

0.17

FR20

0.74

0.80

0.85

0.53

0.36

0.27

FR30L

0.74

0.80

0.85

0.53

0.36

0.27

Table 3.1-6 Soft limit stop time(ms)

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

FR3

430

500

430

310

150

120

FR3-WMS

430

500

430

310

150

120

FR3-WML

430

500

430

310

150

120

FR3-C

430

500

430

310

150

120

FR5

460

540

520

350

190

160

FR5-C

460

540

520

350

190

160

FR10

500

580

550

370

210

180

FR16

480

570

530

360

200

170

FR20

580

640

740

440

300

210

FR30L

580

640

740

440

300

210

Important

According to IEC 60204-1 and ISO 13850, emergency stop device is not a safe protection device. They are supplementary protection measures and do not need to prevent damage.

3.1.10. Power-free movement

If you must move the robot joint but cannot power the robot or other emergencies, please contact the robot dealer. If necessary, you can use violent means to force mobile robots to rescue the trapped persons.

3.2. Equipment transportation

3.2.1. Transportation

Robot and control boxes have been calibrated as complete equipment. Do not separate them, that would require recalibration.

You can only transport the robot in the original packaging. If you want to move the robot in the future, save the packaging material in a dry place.

When the robot moves from the packaging to the installation space, the two arms of the robot are held at the same time. Hold the robot until all the installation bolts of the robot seat are tight.

3.2.2. Carry

According to different models, the total quality (including packaging) is 15kg-80 kg depending on the model. When manpower transports or transfers the collaborative robot, multiple people need to help lift it, don’t recommend single-person handling, it must be stable during transportation. Avoid equipment tilt or slipping.

Warning

  • If you use professional equipment for handling, be sure to use a crane or forklift to transport or carry the collaborative robot by using a crane or forklift, otherwise it may cause personnel damage or other accidents;

  • If you use manual handling, please pay attention to the personal safety on the way to handle;

  • The collaborative robot contains precision components, which should avoid severe vibration or shaking during transportation or transportation, otherwise it may reduce the performance of the equipment.

3.2.3. Storage

The collaborative robot should be stored in -25 ~ 60 ° C, and there is no frost-free environment.

3.3. Maintenance, inspection, and scrapping

3.3.1. Maintenance disposal

Please check the emergency stop and protection stop for 1 month. Determine whether the security function is effective.

Please refer to the wiring chapter for emergency stop and protective stop wiring.

3.3.2. Inspection Plan

3.3.2.1. Preface

3.3.2.1.1. Safety Notice

The following warnings are used in this manual. These warnings are intended to ensure personal and equipment safety. It is important that you observe and follow all assembly instructions and guidelines in other sections of this manual when reading this manual.

Special attention should be paid to the text related to warning signs. Please read the user manual carefully before use. This manual is only used as a customer maintenance instruction manual. Maintenance operators need to have professional competence. Non-professional personnel operation. FAIRINO refuses to assume all responsibilities.

Note

If the robot (robot body, control box, teaching box) is damaged, changed or modified due tohumanreasons,FAIRINO rejects all responsibility; FAIRINO is not responsible for any damage to the robot or any other equipment caused by errors inthe programs written by thecustomer.

3.3.2.1.2. Effectiveness and accountability

The information in this manual does not cover the design, installation and operation of a complete robot application, nor does it cover all peripheral equipment that may affect the safety of this complete system. The complete system is designed and installed to meet safety requirements established in the standards and codes of the country where the robot is installed.

It is the responsibility of FAIRINO integrators to ensure compliance with relevant national laws and regulations and to ensure that there are no significant risks in the complete robot application. This includes but is not limited to the following:

  • Do a risk assessment of the complete robotic system

  • Connect other machinery and additional safety equipment defined by the risk assessment

  • Establish appropriate security settings in software

  • Ensure that users do not modify any security measures

  • Confirm that the design and installation of the entire robot system is correct

  • Clear instructions for use

  • Mark the relevant logo and contact information of the integrator on the robot

  • Collect all documents in technical files, including this manual

3.3.2.1.3. Limited Liability

Any safety information contained in this manual should not be considered a general robot safety guarantee, and even if all safety instructions are followed, it may still cause personal injury or equipment damage.

3.3.2.1.4. Warning signs in this manual

The following symbols define the hazard classification specifications contained in this manual. The same warning signs are used on the products.

Note

../_images/0703.png

Name: Danger

Function: This refers to an electrical situation that is about to cause danger and, if not avoided, could result in death or serious injury.

Note

../_images/0712.png

Name: Electric shockhazard

Function: This refers to an imminent hazardous electric shock situation which, if not avoided, could result in electrocution or serious injury.

Note

../_images/0722.png

Name: Burnhazard

Function: This refers to hot surfaces that may cause hazards and, if touched, may cause injury to persons.

3.3.3. Digital Input/Output Description of Control Box

3.3.3.2. Digital Input Description of Control Box

3.3.3.2.1. Summary of Digital Input of Control Box

The following lists the input types supported by the digital input of Faro robot integrated mini control box, as well as the corresponding wiring diagrams and configuration comparison tables.

../_images/0803.png

Figure 3.3-1 DI0-DI7 General Input Valid Status

Table 3.3-1 Control Box Digital Input Configuration Comparison Table

Control Box Type

Input Type

Connection Diagram

High Level Valid (Switch Closed)

High Level Valid (Switch Open)

Low Level Valid (Switch Closed)

Low Level Valid (Switch Open)

DC Control Box

NPN Output

../_images/0813.png

Invalid

Valid

Valid

Invalid

AC Narrow Voltage Control Box

NPN Output

../_images/0823.png

Invalid

Valid

Valid

Invalid

AC Wide Voltage Control Box

NPN Output

../_images/0833.png

Invalid

Valid

Valid

Invalid

AC Wide Voltage Control Box

PNP Output

../_images/0843.png

Invalid

Valid

Valid

Invalid

3.3.3.2.2. Supported Types of Digital Input of Control Box

The digital input of DC control box and AC narrow voltage control box only supports NPN type input. The digital input of AC wide voltage control box supports optional NPN and PNP types, with NPN type as the default factory setting.

Control Box Type

Input Type

DC Control Box

NPN Input

AC Narrow Voltage Control Box

NPN Input

AC Wide Voltage Control Box

NPN Input/PNP Input

3.3.3.2.3. Wiring Diagram of Digital Input of Control Box

The digital input of DC control box and AC narrow voltage control box only supports NPN type input. The wiring diagram is as follows.

../_images/0853.png

Figure 3.3-2 Wiring Diagram of Digital Input for DC Control Box and AC Narrow Voltage Control Box

The digital input of AC wide voltage control box supports optional NPN and PNP types, with NPN type as the default factory setting. The wiring diagrams are as follows:

Input Type

Connection Diagram

NPN Input

../_images/0863.png

PNP Input

../_images/0873.png

The input type of the wide voltage control box digital input is determined by the DIP switch inside the control box. If the user needs to change the input type, the DIP switch needs to be set to the corresponding position.

DIP Switch Position

DIP Switch Physical Position

NPN Input

EX-24V

../_images/0883.png

PNP Input

EX-0V

../_images/0893.png

3.3.3.3. Digital Output Description of Control Box

3.3.3.3.1. Summary of Digital Output of Control Box

The following lists the output types supported by the digital output of Faro robot integrated mini control box, as well as the corresponding wiring diagrams and configuration comparison tables.

../_images/0913.png

Figure 3.3-4 Control Box DO Output During Power-On

Table 3.3-3 Control Box Digital Output Configuration Comparison Table

Control Box Type

Input Type

Connection Diagram

High Level (Switch Set to ON)

High Level (Switch Set to OFF)

Low Level (Switch Set to ON)

Low Level (Switch Set to OFF)

DC Control Box

NPN Output

../_images/0933.png

Valid

Valid

Invalid

Invalid

AC Narrow Voltage Control Box

NPN Output

../_images/0943.png

Valid

Valid

Invalid

Invalid

AC Wide Voltage Control Box

NPN Output

../_images/0953.png

Valid

Valid

Invalid

Invalid

AC Wide Voltage Control Box

PNP Output

../_images/0963.png

Valid

Valid

Invalid

Invalid

../_images/0923.png

Figure 3.3-5 General Output Valid Status

Table 3.3-4 Control Box Digital Output Configuration Comparison Table

Control Box Type

Input Type

Connection Diagram

High Level Valid (Switch Set to ON)

High Level Valid (Switch Set to OFF)

Low Level Valid (Switch Set to ON)

Low Level Valid (Switch Set to OFF)

DC Control Box

NPN Output

../_images/0933.png

Valid

Invalid

Invalid

Valid

AC Narrow Voltage Control Box

NPN Output

../_images/0943.png

Valid

Invalid

Invalid

Valid

AC Wide Voltage Control Box

NPN Output

../_images/0953.png

Valid

Invalid

Invalid

Valid

AC Wide Voltage Control Box

PNP Output

../_images/0963.png

Valid

Invalid

Invalid

Valid

3.3.3.3.2. Supported Types of Digital Output of Control Box

The digital output of DC control box and AC narrow voltage control box only supports NPN type output. The digital output of AC wide voltage control box supports optional NPN and PNP types, with push-pull structure. It only needs to be wired according to the corresponding wiring diagram without special settings.

Control Box Type

Input Type

DC Control Box

NPN Output

AC Narrow Voltage Control Box

NPN Output

AC Wide Voltage Control Box

NPN Output/PNP Output

3.3.3.3.3. Wiring Diagram of Digital Output of Control Box

The digital output of DC control box and AC narrow voltage control box only supports NPN type output. The wiring diagram is as follows.

../_images/0973.png

Figure 3.3-6 Wiring Diagram of Digital Output for DC Control Box and AC Narrow Voltage Control Box

The digital output of AC wide voltage control box supports NPN and PNP types. The wiring diagrams are as follows:

Input Type

Connection Diagram

NPN Input

../_images/0982.png

PNP Input

../_images/0992.png

3.3.3.4. Inspection maintenance plan

3.3.3.4.1. Robotic arm
  1. Inspection plan

Below is a checklist of checklists that FAIRINO Robots recommends performing based on the marked time intervals. If the inspection reveals that the condition of the relevant parts is unqualified, please correct it immediately.

Note

F=Functional check,V=visual inspection,*=Must be checked after severe collision.

Check item

Monthly

Semi-annually

Annually

1

Check joint rear cover *

V

2

Check joint rear cover screws

F

3

Check joint rubber ring

V

4

Check robot cables

V

5

Check robot cable links

V

6

Check robot base mounting bolts *

F

7

Check End Tool Mounting Bolts *

F

../_images/0732.png
  1. Visual inspection

Note

Do not use compressed air to clean robot arms as it may damage components. Do not store the robot for more than 6 months without visual inspection.

  • If possible, move the robot arm to the zero position.

  • Turn off and disconnect the power cord of the control box.

  • Check the cable between the control box and the robot arm for any damage.

  • Check whether the base mounting bolts are properly tightened.

  • Check whether the tool flange bolts are properly tightened.

  • Check whether the flat ring is worn and damaged.

  • Check all joint backs for any cracks or damage.

  • Check that the screws for the articulated rear cover are seated and tightened correctly.

Note

If the robot shows any damage during the warranty period, please contact the dealer who purchased the robot.

  1. Function check

The purpose of the functional inspection is to ensure that screws, bolts, tools and robot arms are not loose. The screws/bolts mentioned in the inspection planshall be checked with torque wrenches and the torque shall comply with the standard specifications, which can be found in chapter of the Installation Specifications of the User Manual for the specifications of the mounting bolts of the robot arm.

  1. Cleaning

You can wipe off any dust/dirt/grease observed on the robot arm using a cloth and one of the following cleaners: water, isopropyl alcohol, 10% ethanol or 10% naphtha. If the robot is operating in harsh environments, such as cutting fluids, coolants, etc., it is recommended to clean or replacethe rubber ringregularly.

Do not use bleach. Do not use bleach in any diluted cleaning solution.

In rare cases, a very small amount of grease can be seen from the joint. This does not affect the function, use or longevity of the joint.

3.3.3.4.2. Control box, teaching device, button box
  1. Inspection plan

Below is a checklist of checklists that FAIRINO Robots recommends performing based on the marked time intervals. If the inspection reveals that the condition of the relevant parts is unqualified, please correct it immediately.

Note

F=Functional check,V=Visual inspection.

Check item

Monthly

Semi-annually

Annually

1

Emergency stop button on test button box (teach pendant)

F

2

Safety input and output functions on the test terminal strip

F

3

Detection button box start/stop, mode switching function

F

4

Test button box (teach pendant) cable

V

5

Check and clean the air filter on the control box

V

6

Check whether the terminals of the control box are firm

F

7

Ground resistance of detection control box ≤1Ω

F

8

Check the main power supply of the control box

F

../_images/0742.png
  1. Visual inspection

  • Unplug the power cord from the control box.

  • Check that the terminals of the control board are inserted correctly and there are no loose wires.

  • Check whether there is dirt/dust in the control box. Use an ESD vacuum cleaner for cleaning if necessary.

Note

Do not use compressed air to clean the inside of the control box as this may damage components.

  1. Function check

Note

Robot safety features are important and it is recommended to test once a month to ensure proper functionality.

  • Emergency stop button onteach pendant/button box:

    1. Press the emergency stop button on the teach pendant/button box.

    2. Observe that the robot stops and turns off the joint power.

    3. Turn on the robot power again.

      ../_images/0752.png
      ../_images/0763.png
  • Other safety inputs and outputs remain operational

    Check which safety inputs and outputs are active and whether they can be triggered by PolyScope or external devices.

  • Date and clock

    Check that the date and clock in the Log tab are correct. Incorrect dates and clocks indicate low CMOS battery charge. CMOS batteries have a shelf life of up to5 years.

  • Check whether the terminal snaps are in place

    ../_images/0773.png
  1. Cleaning

  • Teaching device

    You may need to clean the teach pendant screen. It is recommended to use a standard mild industrial cleaner that does not contain diluents or any corrosive additives. Do not wipe the screen with abrasive materials. FAIRINO don’t market specific cleaning agents.

  • The button box

    Do not need to be cleaned regularly when it is not normal. If the key identification is blurred and affects the recognition operation, please clean it with detergent at any time.

  • Control box

    The control box contains two filters, one on each side of the control box.

    1. The filter can be observed from the left and right side vents of the control box. Under normal circumstances, you can see the honeycomb structure of the filter.

    2. Remove the filter for cleaning. Clean with low pressure air or change filters as needed. Remember to clean each side. If it is dirty or damaged, replace it (worse, remove the upper cover of the controller and replace the filter from inside the upper cover).

    3. Listen to the sound of the fan when running. If the sound is abnormal, please contact the service provider or replace it.

3.3.3.4.3. Check program registration card
  1. Robotic arm

InspectionItem

Inspected

Inspector

Data

Remark

Check joint rear cover

Check joint rear cover screws

Check joint rubber ring

Check robot cables

Check robot cable links

Check robot base mounting bolts

Check End Tool Mounting Bolts

  1. Control box, teaching device, button box

InspectionItem

Inspected

Inspector

Data

Remark

Emergency stop button on test button box (teach pendant)

Safety input and output functions on the test terminal strip

Detection button box start/stop, mode switching function

Test button box (teach pendant) cable

Check and clean the air filter on the control box

Check whether the terminals of the control box are firm

Ground resistance of detection control box ≤1Ω

Check the main power supply of the control box

3.3.4. Robot waste disposal

FR robots need to be disposed of according to the applicable national laws and regulations and national standards. For details, you can contact manufacturers.

3.4. Installation specifications

3.4.1. Robot arm installation

Important

The recommended robot installation base meets the following requirements to ensure a secure and stable installation of the robot:

(1)The robot mounting base needs to be strong enough and have sufficient load-bearing capacity, which should be able to bear at least 5 times the weight of the robot and at least 10 times the 1-axis torque.

(2)The surface of the robot mounting base should be flat to ensure close contact with the robot contact surface.

(3)The robot mounting base should have sufficient stiffness, be firmly fixed, and not resonate with the robot.

(4)When the robot and other components are moving simultaneously, the mounting base should be separated from other moving components and not fixed together to avoid vibration interference during the movement process.

(5)If the robot is installed on a mobile platform or external axis, the acceleration of the mobile platform or external axis should be as low as possible.

Warning

The following installation methods should be avoided:

(I)Avoid fixing the robot to other moving devices.

../_images/0645.png

Figure 3.4-1 Avoid installing on other sports equipment

Make sure the robot arm is installed correctly and safely. Unstable installation will cause accidents.

Note

You can purchase accurate bases as attachments. Figure 3.4-2、3.4-5、3.4-8、3.4-11 show the position of the sales hole and the location of the screw.

3.4.1.1. Installation requirements for FR3/FR3-WMS/FR3-WML/FR3-C/FR5-C robot

When installing the robot on the mounting base, use four M6 bolts with a strength of not less than 8.8 to fix the robot on the mounting base. The bolts must be tightened with a torque of not less than 10Nm.Suggest using two on the mounting base φ 5mm pin hole matched with pins for robot positioning to improve robot installation accuracy and prevent robot movement due to collisions and other factors.When the robot has high operating accuracy requirements, please be sure to add pins to position the robot.

../_images/0255.png

Figure 3.4-2 FR3/FR3-WMS/FR3-WML/FR3-C/FR5-C model collaborative robot installation size

Important

According to different application scenarios, we recommend several robot installation bases as follows

(I)For situations where the motion speed is not too fast, the running speed is not too large, the accuracy requirements are average, and it is not convenient to fix the robot on the ground, the recommended installation base for the robot is as follows.

../_images/0624.png

Figure 3.4-3 FR3/FR3-WMS/FR3-WML/FR3-C/FR5-C model collaborative robot low requirement mounting base

(II)For situations where the motion speed is fast, the running speed is high, and the accuracy requirements are high, it is recommended to install the robot on the following base and fix it on a solid ground.

../_images/0674.png

Figure 3.4-4 FR3/FR3-WMS/FR3-WML/FR3-C/FR5-C Model Collaborative Robot High Demand Mounting Base

3.4.1.2. Installation requirements for FR5 robot

When installing the robot on the mounting base, use four M8 bolts with a strength of not less than 8.8 to fix the robot on the mounting base. The bolts must be tightened with a torque of not less than 20Nm.Suggest using two on the mounting base φ 8mm pin hole matched with pins for robot positioning to improve robot installation accuracy and prevent robot movement due to collisions and other factors.When the robot has high operating accuracy requirements, please be sure to add pins to position the robot.

../_images/0266.png

Figure 3.4-5 FR5 model collaborative robot installation size

Important

According to different application scenarios, we recommend several robot installation bases as follows

(I)For situations where the motion speed is not too fast, the running speed is not too large, the accuracy requirements are average, and it is not convenient to fix the robot on the ground, the recommended installation base for the robot is as follows.

../_images/0624.png

Figure 3.4-6 FR5 Model Collaborative Robot High Demand Mounting Base

(II)For situations where the motion speed is fast, the running speed is high, and the accuracy requirements are high, it is recommended to install the robot on the following base and fix it on a solid ground.

../_images/0674.png

Figure 3.4-7 FR5 model collaborative robot low requirement mounting base

3.4.1.3. Installation requirements for FR10&FR16 robot

When installing the robot on the mounting base, use four M8 bolts with a strength of not less than 8.8 to fix the robot on the mounting base. The bolts must be tightened with a torque of not less than 25Nm.Suggest using two on the mounting base φ 8mm pin hole matched with pins for robot positioning to improve robot installation accuracy and prevent robot movement due to collisions and other factors.When the robot has high operating accuracy requirements, please be sure to add pins to position the robot.

../_images/0276.png

Figure 3.4-8 FR10&FR16 model collaborative robot installation size

Important

According to different application scenarios, we recommend several robot installation bases as follows

(I)For situations where the motion speed is not too fast, the running speed is not too large, the accuracy requirements are average, and it is not convenient to fix the robot on the ground, the recommended installation base for the robot is as follows.

../_images/0654.png

Figure 3.4-9 FR10&FR16 model collaborative robot low requirement mounting base

(II)For situations where the motion speed is fast, the running speed is high, and the accuracy requirements are high, it is recommended to install the robot on the following base and fix it on a solid ground.

../_images/0674.png

Figure 3.4-10 FR10&FR16 Model Collaborative Robot High Demand Mounting Base

3.4.1.4. Installation requirements for FR20&FR30&FR30L robot

When installing the robot on the mounting base, use six M10 bolts with a strength of not less than 8.8 to fix the robot on the mounting base. The bolts must be tightened with a torque of not less than 45Nm.Suggest using two on the mounting base φ 8mm pin hole matched with pins for robot positioning to improve robot installation accuracy and prevent robot movement due to collisions and other factors.When the robot has high operating accuracy requirements, please be sure to add pins to position the robot.

../_images/0295.png

Figure 3.4-11 FR20&FR30&FR30L model collaborative robot installation size

Important

Because the FR20 and FR30 robots have a large weight and running inertia, it is recommended to be directly fixed on the ground. The recommended base is as follows.

../_images/0664.png

Figure 3.4-12 FR20&FR30 model collaborative robot low requirement mounting base

3.4.2. Tool end installation

There are four M6 thread holes in the robot tool, which can be used to connect the tool to the robot. The M6 bolt must be tightened with 8nm torque, and its strength level is not less than 8.8. In order to accurately regain the tools, please use the nails in the reserved ø6 sales holes.

../_images/0305.png

Figure 3.4-13 FR3/FR3-WMS/FR3-WML/FR3-C/FR5/FR5-C/FR10/FR16 model robot end flange drawing

../_images/0314.png

Figure 3.4-14 FR20/FR30/FR30L model robot end flange drawing

Important

  • Make sure the tools are installed correctly and safely.

  • Ensure the safety architecture of the tools, and no parts of parts fall into danger.

  • Installing M6 bolts with a length of more than 8mm on the robot flange may destroy tool flanges and cause damage that cannot be repaired, causing a tool to change tools.

3.4.3. Installation environment

When installing and using a collaborative robot, make sure to meet the following requirements:

  • Environmental temperature 0-45 ℃

  • Humidity 0% to 90% RH (no condensation)

  • No mechanical impact and shock

  • Altitude requires less than 2000M

  • No corrosive gases, no liquid, no explosive gases, no oil pollution, no salt fog, no dust or metal powder, no radioactive material, no electromagnetic noise, non-flammable items

  • Avoid the device from working under the unstable conditions of the current

  • Users need to add an air switch before the robot power supply, and it is recommended to add an EMC filter

Note

If you want to hang or install the collaborative robot, please contact us.

3.4.4. Floor carrier capacity

Installing the robot on a strong surface, the surface should be sufficient to withstand the weight of the robotic arm at least 5 times, and the surface cannot be vibrated.

3.4.5. Load curves for all FR series models

3.4.5.1. Overview

The load curves in this section are based on the tests of each model under specific trajectories. The load curves of each model have two parts: “full performance” and “extended load capacity”, as follows:

  1. The operating environment of “full performance” is: the friction compensation coefficient of each joint is 1; the collision level of each joint is 10; the web interface is set to 100% operating speed and 360deg/s2 acceleration; dynamics 2.0. In this environment, the “full performance” part of the load curve is suitable for most operating trajectories.

  2. If the end load is in the “extended load capacity”, the “time optimal mode” must be turned on and the acceleration limit must be met, or the robot’s working range must be reduced.

3.4.5.2. Parameter Description

The rated payload of the robot depends on the center of gravity offset of the payload, where the center of gravity offset is defined as the distance between the center of the end flange and the center of gravity of the attached payload.

3.4.5.2.1. FR3 Model Collaborative Robot Load Curve

The maximum load that the FR3 collaborative robot can carry is 5kg, and the rated load is 3kg. The load curve is shown in Figure 1. The specific interpretation of the load curve is as follows:

  1. FR3 can carry a load of 3kg or less at full performance, see the “blue envelope”;

  2. When the load is 3kg to 5kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 360deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0325.png

Figure 3.4-15 FR3 Model Collaborative Robot Load Curve

3.4.5.2.2. FR3-WMS Model Collaborative Robot Load Curve

The maximum load that the FR3-WMS collaborative robot can carry is 5kg, and the rated load is 3kg. The load curve is shown in Figure 1. The specific interpretation of the load curve is as follows:

  1. FR3-WMS can carry a load of 3kg or less at full performance, see the “blue envelope”;

  2. When the load is 3kg to 5kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 360deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0325.png

Figure 3.4-16 FR3-WMS Model Collaborative Robot Load Curve

3.4.5.2.3. FR3-WML Model Collaborative Robot Load Curve

The maximum load that the FR3-WML collaborative robot can carry is 4kg, and the rated load is 3kg. The load curve is shown in Figure 1. The specific interpretation of the load curve is as follows:

  1. FR3-WML can carry a load of 3kg or less at full performance, see the “blue envelope”;

  2. When the load is 3kg to 4kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 360deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/1102.png

Figure 3.4-17 FR3-WML Model Collaborative Robot Load Curve

3.4.5.2.4. FR3-C Model Collaborative Robot Load Curve

The maximum load that the FR3-C collaborative robot can carry is 5kg, and the rated load is 3kg. The load curve is shown in Figure 1. The specific interpretation of the load curve is as follows:

  1. FR3-C can carry a load of 3kg or less at full performance, see the “blue envelope”;

  2. When the load is 3kg to 5kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 360deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/1112.png

Figure 3.4-18 FR3-C Model Collaborative Robot Load Curve

3.4.5.2.5. FR5 Model Collaborative Robot Load Curve

The maximum load that the FR5 collaborative robot can carry is 7kg, and the rated load is 5kg. The load curve is shown in the figure. The specific interpretation of the load curve is as follows:

  1. FR5 can carry a load of 5kg or less at full performance, see the “blue envelope”;

  2. When the load is 5kg to 7kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 360deg/s2;

② Reduce the robot’s working range or reduce the running speed.

../_images/0335.png

Figure 3.4-19 FR5 Model Collaborative Robot Load Curve

3.4.5.2.6. FR5-WML Model Collaborative Robot Payload Curve

The FR5-WML model collaborative robot has a maximum payload capacity of 7kg and a rated payload of 5kg. The payload curve is shown in the figure. The specific interpretation of the payload curve is as follows:

  1. Within the “blue envelope”: Full performance - can run most trajectories with friction compensation coefficients all at 1, dynamics 2.0, 100% speed, 360 deg/s² acceleration (maintenance mode).

  2. Within the “red envelope”: Extended payload capacity - can operate under the following conditions:

① Enable “Time-optimal Mode”;

② Reduce robot working range or lower operating speed.

../_images/1271.png

Figure 3.4-20 FR5-WML Model Collaborative Robot Payload Curve

3.4.5.2.7. FR5-C Model Collaborative Robot Load Curve

The FR5-C model collaborative robot has a maximum payload of 5kg and a rated payload of 4kg. The load curve is shown in the figure as “Full Performance”.

../_images/1302.png

Figure 3.4-21 FR5-C Model Collaborative Robot Load Curve

3.4.5.2.8. FR10 Model Collaborative Robot Load Curve

The maximum load that the FR10 collaborative robot can carry is 14kg, and the rated load is 10kg. The load curve is shown in Figure 3. The specific interpretation of the load curve is as follows:

  1. FR10 can carry a load of 10kg or less at full performance, see the “blue envelope”;

  2. When the load is 10kg to 14kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 180deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0345.png

Figure 3.4-22 FR10 Model Collaborative Robot Load Curve

3.4.5.2.9. FR16 Model Collaborative Robot Load Curve

The maximum load that the FR16 collaborative robot can carry is 20kg, and the rated load is 16kg. The load curve is shown in the figure. The specific interpretation of the load curve is as follows:

  1. FR16 can carry a load of 16kg or less at full performance, see the “blue envelope”;

  2. When the load is 16kg to 20kg, it is the extended load capacity, see the “red envelope”, and the robot can operate in the following states:

① Turn on the “time optimal mode”, and it is recommended to set the acceleration to less than 180deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0355.png

Figure 3.4-23 FR16 Model Collaborative Robot Load Curve

3.4.5.2.10. FR20 Model Collaborative Robot Load Curve

The maximum load that the FR20 collaborative robot can carry is 25kg, and the rated load is 20kg. The load curve is shown in the figure. The specific interpretation of the load curve is as follows:

  1. FR20 can carry a load of 20kg or less at full performance, see the “blue envelope”;

  2. When the load is 20kg to 25kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 150deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0365.png

Figure 3.4-24 FR20 Model Collaborative Robot Load Curve

3.4.5.2.11. FR30 Model Collaborative Robot Load Curve

The maximum load that the FR30 collaborative robot can carry is 35kg, and the rated load is 30kg. The load curve is shown in the figure.

  1. FR30 can carry a load of 30kg or less at full performance, see the “blue envelope”;

  2. When the load is 30kg to 35kg, it is the extended load capacity, see the “red envelope”, at this time the robot can operate in the following states:

① Turn on the “time optimal mode”, it is recommended to set the acceleration to less than 150deg/s2;

② Reduce the robot’s working range or reduce the operating speed.

../_images/0693.png

Figure 3.4-25 FR30 Model Collaborative Robot Load Curve

3.5. Control connection

3.5.1. Controller interface

This series of robots can be equipped with three control boxes with different power inputs. For details on the control box power input, refer to the control box nameplate information. The robot needs to be electrically grounded.

Maximum Input (for customers to configure the front-stage power supply)

Maximum output Output (maximum output peak)

DC 2kW

30-60VDC/30A

2000W/48VDC/41A

DC 5kW

30-60VDC/40A

5000W/48VDC/104A

AC narrow voltage 2kW

176-264VDC/10A/Single Machine/50Hz

2000W/48VDC/41A

AC wide voltage 2kW

100-240VDC/10A/Single Machine/50-60Hz

2000W/48VDC/41A

AC wide voltage 5kW

100-240VDC/16A/Single Machine/50-60Hz

5000W/48VDC/104A

Warning

Before wiring, please ensure that the power supply is turned off and hang a safety warning sign next to it.

The external wiring of this series of robotic arm control systems is connected using pluggable and quickly installable plugs. The wiring panel of the collaborative robot is shown in Figure 3.5-1.

  • Make sure the power button on the control box is off (the button is turned to 0) and connect the power cord to the power socket.

  • Connect the robot body overload cable to the control box overload interface.

  • Insert the button box aviation plug into the control box teaching device interface.

  • The heat dissipation ports on both sides of the control box should be spaced at least 15CM apart.

  • At the front of the control box (user Table metal, switch power button, heavy load and teaching pendant wiring harness), the spacing distance should not be less than 25CM.

  • The control box is 0.6-1.5m above the ground.

  • Do not allow users to replace power cables on their own.

../_images/0375.png

Figure 3.5-1 Robot wiring schematic diagram

3.5.2. Controller I/O panel

You can use the I/O inside the control box to control various devices, including pneumatic relays, PLCs, and limit switches and stop buttons. Figure 3.5-2 shows the electrical interface group of the control box, and Figure 3.5-3 shows the electrical interface group of the integrated mini control box (mini BOX).

../_images/0384.png

Figure 3.5-2 Schematic Diagram of Control Box Electrical Interface

../_images/0394.png

Figure 3.5-3 Schematic Diagram of Integrated Mini Control Box (mini BOX) Electrical Interface

3.5.3. RJ45 network interface group

The network interface group address in the control box is shown in figure below. Note that the graph corresponds to the sequence of the address order of the internal network port of the control box, and the default port of the robot is prohibited from insertion. The user’s network port can be used to communicate with the camera and other devices. The IP address is 192.168.57.2. The button box interface is default to the faculty control port, and the IP address is 192.168.58.2. Use the network cable connection button box interface and computer. The computer IP address is set to 192.168.58.10 or the same network segment as it. You can access the teaching pendant page. Easy to manufacture control boxes to access the pages of the oscillator through the network port of the connection button box.

../_images/0404.png

Figure 3.5-4 Significant diagram of network interface group

3.5.4. End plate

You can use the end -panel’s I/O and 485 communication interfaces to control various devices, including pneumatic relay, PLC and emergency stop buttons. The PIN foot distribution and its PIN foot explanation is shown in figure below. The I/O connector model is M12 connector 8 cores.

Note

End board I/O and 485 interfaces are prohibited from hot plugging.

../_images/0413.png

Figure 3.5-5 The schematic diagram of the end version of the electrical interface

3.5.5. Ground

  1. The control box is located at the M4 combination screw in the upper left of the power switch, as shown in figure below.

../_images/0424.png

Figure 3.5-6 Demonstration diagram of the control box

  1. The body is located on the right side of the base of the base, as shown in figure below.

../_images/0435.png

Figure 3.5-7 Dragon schematic diagram of the body

The protective wire used alone, the cross -sectional area should not be less than:

  • 2.5mm2 copper or 16mm2 aluminum,if mechanical injury protection is provided (wire pipe, pipeline, etc.)

  • 4mm2 copper or 16mm2 aluminum,if no mechanical damage protection is provided

3.5.6. The common specifications of all digital I/O

This section stipulates the electrical specifications of the following control box 24 volt digital input/output:

  • Safety I/O

  • Universal digital amount I/O

Robots must be installed in accordance with electrical specifications.

By configuring the “Power Communication” interface, you can use an internal or external 24V power supply to power the digital I/O. In this interface, the upper two terminals (ex24V and exon) are the 24V and ground of the external power supply, and the lower two terminals (24V and GND) are the 24V and ground of the internal power supply. The default configuration uses the internal power supply, as shown in the following figures for the control box and integrated mini control box (mini BOX).

../_images/0445.png

Control Box

../_images/1342.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-8 Power Communication Schematic 01

If the load power is high, connect an external power supply as shown in the figure below. For the AC wide voltage integrated mini control box (mini BOX), the external power supply and internal power supply share a common 0V connection.

../_images/0455.png

Control Box

../_images/1352.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-9 Power Communication Schematic 02

The electrical specifications of internal and external power are shown in table below Internal and external electrical specifications:

Table 2.5‑1 Internal and external power supply electrical specifications

Terminal

Parameter

Mininum

Typical

Maximum

Unit

Internal 24V power supply
[ex24V -exGND]
[ex24V -exGND]

Voltage
Current

23
0

24
-

25
2

V
A
Internal 24V power supply
[24V- GND]
[24V- GND]

Voltage
Current

23
0

24
-

25
1.5

V
A

The electrical specifications of digital I/O are shown in table below Digital I/O Electric Specifications:

Table 2.5‑2 Digital I/O Electric Specification

Terminal

Parameter

Mininum

Typical

Maximum

Unit

Digital output
[COx/DOx]
[COx/DOx]
[COx/DOx]

Current
Pressure drop
Leakage current

0
0
0

-
-
-

1
0.5
0.1

A
V
mA

[COx/DOx]

function

-

NPN

-

Type

Digital output
[EIx/SIx/CIx/DIx]
[EIx/SIx/CIx/DIx]
[EIx/SIx/CIx/DIx]

OFF
ON
Current(11~30)

-3
11
2

-
-
-

5
30
15

V
V
mA

[EIx/SIx/CIx/DIx]

function

-

NPN

-

Type

The electrical specifications for digital DO loads are shown in the table below.

Table 3.5-3 Electrical Specifications for Single-Channel Digital DO Load

Control Box Type

DO Output Type

Power Supply Type

Maximum Single-Channel DO Load

DC/AC Narrow-Voltage Control Box

NPN Output

External 24V Power Supply

Channels 1-4: 400mA
Channels 5-8: 250mA
Channels 9-16: 125mA

DC/AC Narrow-Voltage Control Box

NPN Output

Internal 24V Power Supply

Channels 1-4: 300mA
Channels 5-8: 190mA
Channels 9-16: 90mA

AC Wide-Voltage Control Box

NPN/PNP Output

External 24V Power Supply

Channels 1-2: 200mA
Channels 3-8: 100mA
Channels 9-16: 60mA

AC Wide-Voltage Control Box

NPN/PNP Output

Internal 24V Power Supply

Channels 1-2: 200mA
Channels 3-8: 100mA
Channels 9-16: 60mA

3.5.7. Safety I/O

This section describes the electrical specifications of security I/O, and must abide by the general electrical specifications in Section 3.5.6.

Safety devices and equipment must be installed in accordance with the safety description and risk assessment, see section 3.1. All security I/O is paired (redundant) and must be stored as two independent branches. Single failures should not cause loss of security function.

Safety I/O includes emergency stop and security stop. Urgent stop input is only used for emergency stop equipment, and safely stops input for various security -related protection equipment. Functional differences are shown in table below:

Table 2.5-3 Functional difference

Emergency stop

Safe stop

Robot stops moving

Yes

Yes

Stop Category

Category 0

Category 1

Program execution

Stop

Pause

Robot power supply

Close

Open

Restart

Manual

Automatic or manual

Frequency of use

Infrequent

Often

Reinitialization required

Need

Needless

Warning

  • Do not connect the security signal to a PLC that does not have the correct and safe level. If this warning does not follow, it may cause serious damage or death because one of the security stop function may be covered. Security interface signals must be separated from normal I/O interface signals.

  • All I/O is a redundant -related I/O built (two independent channels). Two channels must be kept separately so that a single failure will not cause security function.

  • Before the robot is put into operation, it is necessary to verify the emergency stop safety function (the robot is powered on, press the emergency stop button, the robot is disconnected, the power is turned off, the rotating emergency stop button, the power is turned on, and the robot is re -power to enable it). Safety functions must be tested regularly.

  • Robot installation should comply with these specifications. Otherwise, it may lead to severe damage or death, because the safety stop function may be over.

The following sections are given some examples of how to use security I/O.

Default safety configuration When the robot leaves the factory, it has the default configuration. It can be operated without any additional safety devices. Please refer to figure below.

../_images/0494.png

Control Box

../_images/1362.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-10 Safety protection schematic diagram 01

Connect the emergency stop button In most applications, one or more additional emergency stop buttons need to be used. Please refer to figure below.

../_images/0504.png

Control Box

../_images/1372.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-11 Safety protection schematic diagram 02

Connect the security stop button An example of a safe stop device is the door switch that the robot stops when the door is turned on. Please refer to figure below.

../_images/0514.png

Control Box

../_images/1382.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-12 Safety protection schematic diagram 03

3.5.8. Universal digital amount I/O

This section describes the electrical specifications of the general digital I/O, and must abide by the general electrical specifications in Section 3.5.6.

The general digital amount I/O can be used to drive relays, solenoid valves and other devices or interact with other PLCs.

Digital quantity output control load

This example demonstrates how to connect the digital quantity output to control the load, Please refer to figure below.

../_images/0523.png

Control Box

../_images/1392.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-13 Great digital quantity output schematic diagram 01

3.5.9. Digital input from the button

The following example demonstrates how to connect the simple button to the digital quantity input.

../_images/0533.png

Control Box

../_images/1402.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-14 Great digital quantity output schematic diagram 02

3.5.10. Interact with other devices or PLC

The following example demonstrates how to interact with other devices or PLC digital input output.

../_images/0543.png

Control Box

../_images/1412.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-15 Interactive diagram with other devices or PLC

3.5.11. Simulation I/O

Table 2.5-4 Simulation current voltage

Terminal

Parameter

Mininum

Typical

Maximum

Unit

Analog current input
[AIx-END]
[AIx-END]
[AIx-END]

Current
Impedance
Resolution

0
-
-

-
500
12

20
-
-

mA
ohm
bit
Analog voltage input
[AIx-END]
[AIx-END]
[AIx-END]

Voltage
Impedance
Resolution

0
-
-

-
510
12

10
-
-

V
Kohm
bit
Analog current input
[AOx-END]
[AOx-END]
[AOx-END]

Current
Voltage
Resolution

0
0
-

-
-
12

20
10
-

mA
V
bit
Analog voltage input
[AOx-END]
[AOx-END]
[AOx-END]
[AOx-END]

Voltage
Current
Impedance
Resolution

0
0
-
-

-
-
100
12

10
20
-
-

V
mA
ohm
bit

The simulation I/O is used to set or measure the voltage (0-10V) or current (0-20mA) of other devices.

In order to achieve high precision, the following methods are recommended.

  • The equipment and control box use the same ground (GND).

  • Use shielding cables or twisted wires.

The following example demonstrates how to use analog I/O.

Use analog output

The following example is to demonstrate the use of analog output control conveyor belt.

../_images/0564.png

Control Box

../_images/1422.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-16 Simulation output schematic diagram

Use analog input

The following example is to demonstrate the simulation input connection simulation sensor.

../_images/0574.png

Control Box

../_images/1432.png

Integrated Mini Control Box (mini BOX)

Figure 3.5-17 Simulation input schematic diagram

3.5.12. FR3MT&3C Optional Modules

3.5.12.1. Preface

The definition of collaborative robots complies with international ISO standards and national regulations to ensure operator safety. We do not recommend directly applying the robot body in scenarios where the operation target is the human body. However, if the robot user or developer has a specific need to involve human targets, they must conduct thorough evaluations and ensure personnel safety by configuring a reliable, fully tested, and certified safety protection system for the robot body.

3.5.12.1.1. Safety Notice

This manual serves only as a safety certification guide for customers. Maintenance operators must possess professional expertise. FaRo (法奥) assumes no responsibility for any incidents caused by non-professionals.

Important

If the robot (robot body, power module, or extension module) is damaged, altered, or modified due to human factors, FaRo refuses to bear any responsibility. FaRo is not liable for any damage caused to the robot or other equipment due to programming errors made by the customer.

3.5.12.1.2. Validity and Responsibility

The information in this manual does not cover the design, installation, or operation of a complete robot application, nor does it account for all peripheral devices that may affect the safety of the system. The design and installation of the complete system must comply with the safety requirements established by the standards and regulations of the country where the robot is installed.

FAIRINO integrators are responsible for ensuring compliance with relevant national laws and regulations, guaranteeing that the complete robot application poses no significant hazards. This includes but is not limited to:

  • Conducting a risk assessment for the complete robot system

  • Connecting additional mechanical and safety devices as defined in the risk assessment

  • Establishing appropriate safety settings in the software

  • Ensuring users do not modify any safety measures

  • Verifying the correct design and installation of the entire robot system

  • Providing clear usage instructions

  • Marking the integrator’s logo and contact information on the robot

  • Collecting all documentation, including this manual, in the technical file

3.5.12.1.3. Limited Liability

The safety information in this manual does not constitute a general safety guarantee for robots. Even if all safety instructions are followed, personnel injury or equipment damage may still occur.

3.5.12.1.4. Safety Warning Signs

The following safety warning signs are used on the product.

Important

../_images/0085.png

Name: DANGER

Purpose: Indicates an imminent electrical hazard that could result in death or serious injury if not avoided.

Important

../_images/0094.png

Name: ELECTRIC SHOCK HAZARD

Purpose: Indicates an imminent electric shock hazard that could result in death or serious injury if not avoided.

Important

../_images/0105.png

Name: BURN HAZARD

Purpose: Indicates a hot surface that could cause injury if touched.

Important

../_images/1122.png

Name: GROUNDING

Purpose: Indicates that the device must be properly grounded.

3.5.12.2. FR3MT&3C Base and Module Interface Definitions

3.5.12.2.1. Base Interface Definitions

The base of the robot has seven external buttons and interfaces, defined as follows:

../_images/1132.png

Figure 3.5-18 Base Buttons and Interfaces

Note

The pin definitions for base interfaces are viewed from the installation reference plane.

1. Controller Power Button: Powers on automatically by default.

2. M8-A Type-4P-Female Socket Pin Definitions: User Ethernet port (IP: 192.168.57.2). Connector: M8-A Type-4P-Female (with M8-A Type-4P-Male plug). Complies with IEC 61076-2-101.

../_images/1142.png

Pin

Definition

Description

1

TX+

Data Transmit Positive

2

RX+

Data Receive Positive

3

RX-

Data Receive Negative

4

TX-

Data Transmit Negative

3. M12-L Type-5P-Male Socket Pin Definitions: Connector: M12-L Type-5P-Male (with M12-L Type-5P-Female plug). Complies with IEC 61076-2-101.

../_images/1152.png

Pin

Color

Definition

Description

Remarks

1

Black

0V

Control Power Negative

Robot control power negative (backup power, no connection needed)

2

Brown

24V

Control Power Positive

Robot control power positive (backup power, no connection needed)

3

White

48V

Power Supply Positive

Robot power supply positive

4

Blue

0V

Power Supply Negative

Robot power supply negative

5

Gray

PE

Ground

Safety ground

Note

① The base includes a 48V-to-24V power converter. ② The 48V-to-24V converter serves as a backup for the 24V input.

../_images/1162.png

Figure 3.5-19 48V-to-24V Power Conversion Diagram

4. M12-A Type-12P-Female Socket Pin Definitions: Connector: M12-A Type-12P-Female (with M12-A Type-12P-Male plug). Complies with IEC 61076-2-101.

../_images/1172.png

Pin

Definition

Description

Remarks

1

AGND

Analog Ground

Analog reference ground

2

0V

24V Power Negative

Control power negative

3

485-A

RS485 Communication A

Reserved for expansion

4

485-B

RS485 Communication B

Reserved for expansion

5

DI0/DO0

Digital Input/Output 0

Configurable as input or output (mutually exclusive)

6

DI1/DO1

Digital Input/Output 1

Configurable as input or output (mutually exclusive)

7

DI2/DO2

Digital Input/Output 2

Configurable as input or output (mutually exclusive)

8

AI0/AO0

Analog Input/Output 0

Configurable as input or output (mutually exclusive)

9

AI1/AO1

Analog Input/Output 1

Configurable as input or output (mutually exclusive)

10

24V

24V Power Positive

Control power positive

11

DI3/DO3

Digital Input/Output 3

Configurable as input or output (mutually exclusive)

12

DI4/DO4

Digital Input/Output 4

Configurable as input or output (mutually exclusive)

5. M8-A Type-4P-Female Socket Pin Definitions: Debug Ethernet port (IP: 192.168.58.2). Connector: M8-A Type-4P-Female (with M8-A Type-4P-Male plug). Complies with IEC 61076-2-101.

../_images/1142.png

Pin

Definition

Description

1

TX+

Data Transmit Positive

2

RX+

Data Receive Positive

3

RX-

Data Receive Negative

4

TX-

Data Transmit Negative

6. USB-A Port: USB 2.0 for internal debugging. 7. HDMI-A Port: HDMI display for internal debugging.

3.5.12.2.2. Power Module Interface Definitions

The power module uses a Meanwell NDR-480-48. Pin definitions:

../_images/1182.png

Pin

Definition

Description

Remarks

1

L

Live Wire

Input 100-240V AC

2

N

Neutral Wire

Input 100-240V AC

3

PE

Ground

Earth connection

4

+V

48V

Output 48V/10A

5

+V

48V

Output 48V/10A

6

-V

0V

Output 48V return

7

-V

0V

Output 48V return

3.5.12.2.3. Extension Module Interface Definitions

The extension module includes emergency stop and energy discharge functions. External terminals and internal topology:

../_images/1192.png

Pin

Definition

Description

1

48-IN

48V Input Positive

2

0V

48V Input Negative

3

PE

Ground

4

PE

Ground

5

24V

Control Power Positive

6

0V

Control Power Negative

7

0V

Power Supply Negative

8

48-OUT

Power Supply Positive

9

ESW1

Emergency Stop Button 1 Positive

10

0V

Emergency Stop Button 1 Negative

11

ESW2

Emergency Stop Button 2 Positive

12

0V

Emergency Stop Button 2 Negative

13

E-O-2

Passive Normally Open 2

14

E-O-1

Passive Normally Open 1

15

E-C-2

Passive Normally Closed 2

16

E-C-1

Passive Normally Closed 1

3.5.12.3. FR3MT&3C Application Scenarios

Most scenarios only require the user cable kit. Specific use cases:

No.

Scenario

Power Supply

Functional Requirements

Recommended Configuration

1

Basic Application

48V/10A DC available

No E-stop/energy discharge

User cable kit

2

Safety Extended

48V/10A DC available

E-stop + energy discharge

User cable kit + extension module

3

Independent Power

No 48V/10A DC

No E-stop/energy discharge

User cable kit + power module + power cord

4

Full Function

No 48V/10A DC

E-stop + energy discharge

User cable kit + power module + power cord + extension module

3.5.12.3.1. Basic Application

Only user cable kit required. Connection steps:

  1. Connect the M12-L-5P-Female power cable to the base (48V/0V/PE to user power supply; insulate 24V/0V).

  2. Connect M12-A-12P-Male and M8-A-4P-Male to base.

../_images/1202.png

Figure 3.5-20 Only user cable kit required connection steps

3.5.12.3.2. Safety Extended

User cable kit + extension module. Connection steps:

  1. Connect the 0.5M extension cable (48V/0V/PE) to user power and module.

  2. Connect M12-L-5P-Female to base (all 5 wires to module).

  3. Connect M12-A-12P-Male and M8-A-4P-Male to base.

../_images/1212.png

Figure 3.5-21 User cable kit + extension module connection steps

3.5.12.3.3. Independent Power

User cable kit + power module + power cord. Connection steps:

  1. Connect 1.5M power cord (L/N/PE) to NDR-480-48 input.

  2. Connect M12-L-5P-Female to base (48V/0V/PE to power module; insulate 24V/0V).

  3. Connect M12-A-12P-Male and M8-A-4P-Male to base.

../_images/1222.png

Figure 3.5-22 User cable kit + power module + power cord connection steps

3.5.12.3.4. Full Function

User cable kit + power module + power cord + extension module. Connection steps:

  1. Connect 1.5M power cord (L/N/PE) to NDR-480-48.

  2. Connect 0.5M extension cable (48V/0V/PE) between power module and extension.

  3. Connect M12-L-5P-Female to base (all 5 wires to module).

  4. Connect M12-A-12P-Male and M8-A-4P-Male to base.

../_images/1232.png

Figure 3.5-23 User cable kit + power module + power cord + extension module connection steps

3.5.12.4. Optional Parts List

User Cable Kit (5M):

No.

Name

Qty

1

FR3MT&3C-DC Power Cable-5M

1

2

FR3MT&3C-I/O Cable-5M

1

3

FR3MT&3C-Ethernet Cable-5M

1

4

M8 Straight Plug, M8-P4A-PLA05, 4-pin

1

User Cable Kit (1M):

No.

Name

Qty

1

FR3MT&3C-DC Power Cable-1M

1

2

FR3MT&3C-I/O Cable-1M

1

3

FR3MT&3C-Ethernet Cable-1M

1

4

M8 Straight Plug, M8-P4A-PLA05, 4-pin

1

Power Module:

No.

Name

Qty

1

Meanwell Power Supply, NDR-480-48

1

Power Cord:

No.

Name

Qty

1

FR3MT&3C-Power Cord-1.5M

1

Extension Module:

No.

Name

Qty

1

FR3MT&3C Base-Extension Module

1

2

FR3MT&3C Power-Extension Cable-0.5M

1

3.6. Demonstrate and end LED

The robotic teaching pendant can use a computer or tablet to access and control the robot. The connection method can refer to Section 3.5.3 to explain. In addition, users can also use our FR-HMI osteter.

3.6.1. Introduction to the button box

3.6.1.1. 60 Button Box (POE) (BX01)

../_images/0584.png

Figure 2.6-1 60 Button Box (POE) (BX01)

Emergency stop switch: When pressing the emergency stop switch, the robot enters the state of emergency stop.

Type-c:Connect the port of the web teaching pendant.

Button 1:Short press automatic/manual mode switch, long press and enter/exit the drag mode.

Button 2:Short press the record to show the teaching point, long press and enter/exit the state of no demonstrator.

Button 3:Start/stop running program.

3.6.1.2. 60 Button Box (POE) (BX02)-V1.0

../_images/0594.png

Figure 2.6-2 60 Button Box (POE) (BX02)-V1.0

Emergency stop switch:When pressing the emergency stop switch, the robot enters the state of emergency stop.

Start/Stop:Start/stop running program.

Ethernet:Connect to the web teaching pendant.

Turn off:No enabled.

Record point:Record the teaching point.

Teaching mode:Enter/exit with the teaching pendant state.

Working mode:Automatic/manual mode switch.

Drag mode:Enter/exit drag mode.

3.6.1.3. 60 Button Box (POE) (BX02) - V2.0

../_images/0793.png

Figure 3.6-3 60 Button Box (POE) (BX02) - V2.0

Emergency stop switch: When the emergency stop switch is pressed, the robot enters an emergency stop state.

Start/Stop: Start/Stop running the program.

Network port: Connect to a web teaching pendant.

IP reset: Reset the network port IP.

Record point: Record teaching points.

One click clear: Clear all recoverable errors.

Operation mode: Automatic/Manual mode switching.

Drag mode: Enter/exit drag mode.

3.6.2. FR-HMI Teach pendant introduction

../_images/0604.png

Figure 2.6-3 FR-HMI teaching pendant front

../_images/0614.png

Figure 2.6-4 FR-HMI teaching pendant back

Display:Touch operation and display interface of the teaching pendant.

Start key:Start the program.

Stop key:Stop the currently running program.

Joint button:The joint node of the robot.

Three -bit enable:Manual mode enable robots

Emergency stop switch:When pressing the emergency stop switch, the robot enters the state of emergency stop.

Mode key:Rotate the button to switch the automatic mode.

3.6.3. End LED definition

Table 3.6‑1 The end LED definition table

Function

LED color

When communication is not established

“Off”, “Red”, “Green” and “Blue” alternately

Automatic mode

Blue long bright

Manual mode

Green long bright

Drag Mode

White cyan long bright

Button box record point (only when using button box)

Purple blinks twice

Start running (only when using the button box)

Cyan blue flashes twice

Enter the state of unmatched button box (only when using the button box)

Blue flashes twice

Stop operation (only when using the button box)

Red flashes twice

Error reporting (only when using the button box)

Red long bright

Zero calibration completed

White cyan flashes three times

Enable

Yellow flashes twice