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

Figure 3.1-1 FR3 model collaborative robot

Figure 3.1-2 FR3-WMS model collaborative robot

Figure 3.1-3 FR3-WML model collaborative robot

Figure 3.1-4 FR3-C model collaborative robot

Figure 3.1-5 FR5 model collaborative robot

Figure 3.1-6 FR5-WML model collaborative robot

Figure 3.1-7 FR10 model collaborative robot

Figure 3.1-8 FR16 model collaborative robot

Figure 3.1-9 FR20 model collaborative robot

Figure 3.1-10 FR30 model collaborative robot

Figure 3.1-11 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

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

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

Important

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)

Table 3.1-2 Category 0 stop time (ms)

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)

Table 3.1-4 Safety stop time(ms)

Table 3.1-5 Soft limit stop distance(rad)

Table 3.1-6 Soft limit stop time(ms)

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

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

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

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

3.3.3.1. Precautions When Switching Digital Related Functions of Control Box

Important

1. When switching digital input/output functions, the safety operation procedures of the robot must be followed to ensure the safety of operators and equipment.

2. Avoid switching digital input/output functions during robot operation to prevent affecting the normal operation of the robot.

3. Before switching digital input/output functions, the power supply of the robot must be cut off to prevent electric shock and unexpected machine movement, which may cause personal injury and equipment damage.

4. Before switching functions, the requirements of the robot control system for digital input/output must be clarified, including signal type, voltage level, load capacity, etc.

5. Ensure that the connection between digital input/output ports and external devices is correct, including whether the wiring is secure and whether the ports match.

6. Avoid repeated signal allocation to ensure that each signal is uniquely allocated.

7. After allocation is completed, the robot control system must be restarted to make the settings take effect.

8. After completing the configuration, enter the I/O status interface to check whether the status of digital input/output signals is correct.

9. Verify whether the digital input/output functions are working properly through actual operation or writing test programs.

10. If digital input/output signals are related to program logic, check whether the processing of these signals in the program is correct.

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.

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		Invalid	Valid	Valid	Invalid
AC Narrow Voltage Control Box	NPN Output		Invalid	Valid	Valid	Invalid
AC Wide Voltage Control Box	NPN Output		Invalid	Valid	Valid	Invalid
AC Wide Voltage Control Box	PNP Output		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.

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.

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
PNP Input

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
PNP Input	EX-0V

3.3.3.2.4. Software Settings Related to Digital Input of Control Box

The only software setting item for digital input is “DI0-DI7 General Input Valid Status”, which represents the digital voltage level value corresponding to the detected valid input. This setting allows users to use digital input more flexibly.

The comparison table of valid status detected by the software under different settings of “DI0-DI7 General Input Valid Status” when the external switch of digital input is in different states is as follows:

Table 3.3-2 Valid Status Comparison Table

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.

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		Valid	Valid	Invalid	Invalid
AC Narrow Voltage Control Box	NPN Output		Valid	Valid	Invalid	Invalid
AC Wide Voltage Control Box	NPN Output		Valid	Valid	Invalid	Invalid
AC Wide Voltage Control Box	PNP Output		Valid	Valid	Invalid	Invalid

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		Valid	Invalid	Invalid	Valid
AC Narrow Voltage Control Box	NPN Output		Valid	Invalid	Invalid	Valid
AC Wide Voltage Control Box	NPN Output		Valid	Invalid	Invalid	Valid
AC Wide Voltage Control Box	PNP Output		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.

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.

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
PNP Input

3.3.3.3.4. Software Settings Related to Digital Output of Control Box

There are two software setting items for digital output: “Control Box DO Output During Power-On” and “DO0-D07 General Output Valid Status”. “Control Box DO Output During Power-On” represents the output level during the power-on period of the control box when the control system has not completed initialization. It can correspond to different output valid states, which can flexibly meet the requirements for output status during power-on. “General Output Valid Status” represents the digital output voltage level value that needs to be controlled when the output is valid. This setting allows users to use digital output more flexibly.

1. The comparison table of valid status under different settings of “Control Box DO Output During Power-On” is as follows:

   

   Figure 3.3-7 Control Box DO Output During Power-On

Table 3.3-5 Valid Status Comparison Table

2. The comparison table of valid status under different settings of “DO0-D07 General Output Valid Status” is as follows:

   

   Figure 3.3-8 DO0-D07 General Output Valid Status

Table 3.3-6 Valid Status Comparison Table

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.

2. 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.

3. 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.

4. 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.