JAKA ROBOTICS
User Manual-Hardware
This manual also applies to Zu pro series
JAKA Zu 5
Page 1: ...JAKA ROBOTICS User Manual Hardware This manual also applies to Zu pro series JAKA Zu 5 ...
Page 2: ...JAKA ROBOTICS User Manual Robot Serial Number Cabinet Serial Number JAKA Zu 5 ...
Page 3: ...ther users of JAKA robots must be familiar with JAKA robot programming and system integration IP class of Zu series is IP54 IP class of Zu pro series is IP65 How to Read This Manual This manual mainly contains the safety notice mechanical and electrical interfaces installation and Maintenance For software usage please refer to the software part This manual will be a big help in both installation a...
Page 4: ...RVIEW OF ROBOT CONFIGURATIONS 11 2 2 OPERATION TERMINAL 11 2 3 ROBOT ARM 12 2 3 1 Robot End 12 2 3 2 Flange Buttons and interfaces 13 2 4 ELECTRICAL CABINET AND CONTROL STICK 14 3 MECHANICAL SPECIFICATION 16 3 1 ROBOT WORKING RANGE 17 3 1 1 Robot Dimensions 17 3 1 2 Robot Working Range 17 3 2 INSTALLATION 18 3 2 1 General installation steps 18 3 2 2 Important safety instructions 19 3 2 3 Robot Bod...
Page 5: ...TOOL INPUT AND OUTPUT 33 4 5 1TIO function description 33 4 6 TECHNICAL SPECIFICATIONS 35 5 MAINTENANCE AND REPAIR 37 5 1 SAFETY INSTRUCTIONS 37 5 3 1 Filter cleaning and replacement 40 5 3 2 Part preservation 40 6 APPLIED STANDARDS AND CERTIFICATES 43 6 1 COLLABORATIVE ROBOT CERTIFICATION 43 6 2 INDUSTRIAL ROBOT CERTIFICATION 44 6 3 FUNCTIONAL SAFETY CERTIFICATION 45 6 4 CE EMC CERTIFICATES 48 6 ...
Page 6: ...on efficiency What Do the Boxes Contain Item Amount Robot 1 Electrical cabinet 1 Key to cabinet 1 Power Supply Cable 1 JAKA Certificate of Quality 1 User Manual 1 Warranty Card 1 JAKAZu 5 is at your service Think what you think and do what you do JAKAZu 5 is an intelligent light weight 6 DOF modularized collaborative robot with a payload of 5kg and belongs to the JAKA Zu Modularized Collaborative ...
Page 7: ...ich if touched could result in injury 1 3 Safety Precautions This section is mainly for the protection of operators and related matters that need to be paid attention to during the first installation Users need to carefully read the safety warnings in this manual We describe various situations as much as possible although the description cannot be exhaustive 1 Make sure to install the robot and al...
Page 8: ... Combining different machines might increase hazards or create new hazards Always make an overall risk assessment for the complete installation 7 Never modify the robot A modification might create hazards that are unforeseen by the integrator JAKA DISCLAIMS ANY LIABILITY IF THE PRODUCT IS CHANGED OR MODIFIED IN ANY WAY 1 The robot and electrical cabinet generate heat during operation Do not handle...
Page 9: ...at the operator can understand the working range of the robot with the end effector gripper tool etc mounted 5 Make sure that safety measures and or robot safety configuration parameters have been set up to protect both programmers operators and bystanders as defined in the risk assessment The lock should be set as needed so that the non operator cannot access the robot power supply 6 In emergency...
Page 10: ...his includes but is not limited to the following Use in potentially explosive environments Use in medical and life critical applications Use before performing a risk assessment Use where the rated performance levels are insufficient Operation outside the permissible operating parameters 1 7 Emergency Stop When an emergency occurs press the emergency stop button to stop all movement of the robot im...
Page 11: ...amage the joints 2 If the brake is released manually gravitational pull can cause the robot arm to fall Always support the robot arm tool and work item when releasing the brake 1 9 Precautions for Transportation and Handling Transport the robot in the original packaging Save the packaging material in a dry place you may need to pack down and move the robot later on Lift both tubes of the robot arm...
Page 12: ...ns and software usages please refer to other chapters During using of JAKA Zu robots if quick help is needed feel to free to call our hotline 86 400 006 2665 As shown in Fig 2 1 JAKA Zu robots uses wireless connection and the followings are needed Operation Terminal Device used to program and set robot Robot Arm The core moving part of robot to achieve designated movements And at the end of the ar...
Page 13: ...bot arm is shown as Fig 2 1 and is composed of six rotation joints with two linkages And at the end of the arm a ring indicator buttons used to drag and tech TIO interface are located Fig 2 1 Robot Arm 2 3 1 Robot End At the end of the robot an indicator and a pause button is located The indicator and the pause button is located as Fig 2 2 and the meanings of different color are listed in table 2 ...
Page 14: ...n should be evaluated carefully the contact of robot and personnel could cause server injury of personnel or damage of equipment 2 3 2 Flange Buttons and interfaces On the side of flange located two buttons and TIO interface The buttons are FREE button and POINT button Respectively shown as below The detailed description of TIO is in chapter 4 When the free button is pressed the robot would enter ...
Page 15: ...mands can be sent to the robot using buttons on the stick and are described as follows table 2 3 Stick Function Description ON OFF ON Press the power button for 1 second and release it The buzzer will ring and the electric control cabinet will start up OFF Press and hold the power button for more than 3s the handle buzzers 6 7 times and the electric control cabinet is turned off Power Enable Turn ...
Page 16: ...the lock indicator light will be orange Unlock handle Press and hold the lock button for 3 seconds and the lock indicator light will go out Combination function Other buttons and lock button can be pressed in combination Lock indicator Locked state When locked the indicator is orange Except for the unlock and on off button other buttons are invalid APP can control the robot Unlocked state When unl...
Page 17: ...Fig3 1 The base is used to install the robot and the tool end is used to mount the tool The tool can perform translational and rotational movements in the robot s working range The following sections describe the basics to be aware of the installation of various components in the robot system Fig 3 1 JAKA Zu 5 ...
Page 18: ...nd electrical cabinet are shown in Fig 3 2 and Fig3 3 Make sure to take into account the working range of the robot during installation to avoid injury to people or damage to the equipment 3 1 2 Robot Working Range The working range of JAKAZu 5 is shown in Fig 3 4 When choosing the robot installation JAKAZu 5 ...
Page 19: ...because it causes the joints to move fast even though the tool is moving slowly causing the robot to work inefficiently and making it difficult to conduct a risk assessment Fig3 4 3 2 Installation 3 2 1 General installation steps 1 Determine the working range of the robot 2 Mount the robot on the base 3 Install the required tools at the end of the robot JAKA Zu 5 ...
Page 20: ...d in water or in a wet environment 3 2 3 Robot Body Installation The robot has an attitude and position adaptation function It can be mounted in various ways such as ground wall and celling mounting As shown in Fig 3 5 Fig 3 5 Using four M8 bolts to mount the robot through the four 9mm through holes on the robot base It is recommended to tighten these bolts with a torque of 40 Nm If you need to ad...
Page 21: ... flange has four M6 tapped holes to mount the end effector When screws are installed in these threaded holes the screws need to be tightened with a torque of 15 Nm If you need to adjust the tool position very accurately you can also drill a φ6 pin hole and fix it with a pin Fig 3 7 shows the drilling position and the screw mounting position All measurements are in mm Fig 3 7 JAKA Zu 5 ...
Page 22: ...he safety interface signal from the normal I O interface signal 2 All safety signals are redundant two independent channels Keeping the two channels independent ensures that no safety features are lost in the event of a single failure 3 For an introduction to the I O functions inside the electrical cabinet please refer to Section 4 3 Warning 1 Please ensure that all equipment that is not wet is ke...
Page 23: ...ble after extended testing and shielded cables are required if necessary 4 3 Front panel of the electrical cabinet The front panel interface of the electrical cabinet is arranged on the first floor after the electrical cabinet door is opened including 16 digital inputs P1 and P3 16 digital outputs P2 and P4 2 configurable analog interfaces P5 1 set of high speed interface P6 Remote ON OFF and 485 ...
Page 24: ...al output PNP Type 1A continuous current output capability 6 DO6 6th digital output PNP Type 1A continuous current output capability 7 DO7 7th digital output PNP Type 1A continuous current output capability 8 DO8 8th digital output PNP Type 1A continuous current output capability 9 16 V Isolated power input negative default shorting is connected to internal GND P3 DI 9 16 Digital Input 1 DI9 9th d...
Page 25: ...ative encoder A 4 5 2P Differential signal 2 input positive encoder B 12 13 2N Differential signal 2 input negative encoder B 6 7 3P Differential signal 3 input positive encoder Z 10 11 3N Differential signal 3 input negative encoder Z 9 16 DG Digital ground P7 1 2 VSB Internal power supply 5V 100mA max can be used for remote power on off 3 0V Internal GND internal 24V 12V reference ground 4 5 485...
Page 26: ...divided into V power selection security I O configuration The electrical cabinet supports 16 digital inputs and 16 digital outputs as shown in Figure 4 2 Figure 4 2 The digital I O can be powered by a 24V power supply provided inside the control cabinet and supports up to 1 5A output overload will turn off the output When the user needs more power output the V power supply can be powered by an ext...
Page 27: ... 2 and SI1 2 are both connected to V V is connected to 24V and V is connected to 0V it indicates that 24V power is provided inside the electrical cabinet As shown in Figure 4 4 Figure 4 4 2 Connect the emergency stop switch The user needs to use one or more additional emergency stop or guard stop switches please refer to Figure 4 5 and Figure 4 6 for wiring Figure 4 5 and Figure 4 6 show how to us...
Page 28: ... Protective stop function support automatic recovery The electrical cabinet door switch is an application case of the protection stop device and the robot stops when the electrical cabinet door is opened The wiring diagram is shown in Figure 4 7 Fig 4 7 JAKAZu 5 ...
Page 29: ...ault uses internal 24V power supply The high level range is 15 24V and the low level range is 0 11V Users can also connect DIx to V directly Different types of input signals have different connections The specific connection methods are as follows a Dry contact signal as input Figure 4 9 During dry contact input one of the wires is connected to V and the other wire is connected to DIx When the cir...
Page 30: ...nterface is changed 4 3 3 Digital Output DO Figure 4 11 The electric control cabinet has 16 channels PNP type output interface DO1 DO16 to support isolated signal output The digital output uses a high side output with a single continuous maximum current of 1A However when V defaults to internal 24V power supply the 24V power supply is limited to 1 5A The typical internal circuit diagram is as foll...
Page 31: ...electrical cabinet has 2 analog input and output interfaces Ch1 Ch2 the input mode can be configured and the AI mode is as follows 1 Current signal input 4 to 20 mA 2 Voltage signal input 0 5V 0 10V 10V 10V 3 Current signal output 0 20mA 4 Voltage signal output 0 5V 0 10V 10V 10V The wiring method for analog input and output is shown in Figure 4 13 Figure 4 14 The JAKA CAB V2 AI O interface can be...
Page 32: ...o 12V power supply or VSB interface through the switch 4 3 7 Safety I O In order to ensure the safety function configuration of the robot the electrical cabinet provides two fixed safety function input interfaces EI is an emergency stop and SI is the user stop Both EI and SI have a redundant design that can be enabled when any channel signal is active The emergency stop function is similar to the ...
Page 33: ... is configured to be 10A at the factory The power source used by the robot should be equipped with at least grounding mains fuse Residual current circuit breaker It is recommended to install a power switch for the power supply of all devices in the robot s environment Warning 1 Make sure that the robot is grounded correctly Electrical connection to earth 2 Make sure that the input power to the ele...
Page 34: ...he customer needs to choose the TIO external cable please call 400 006 2665 Figure 4 17 shows the cable specifications Figure 4 17 Cable specifications 4 5 1 TIO function description The TIO interface function is described in the following table PIN DEFINE I O Line color DESCRIPTION 1 24V red 24V positive Maximum continuous current to 1 0A 2 DI1 I blue Digital input 1 NPN type Optocoupler Cathode ...
Page 35: ...D gray GND 24V Power Ground 1 TIO analog input interface Analog input AI1 supports 10V 10V high precision voltage range input 2 TIO digital input interface The digital input uses the optocoupler cathode input and is active low Internally connected 4 7k resistors Figure 4 18 a Type of the dry contact input Figure 4 19 The dry contact input ie switch input is connected to the negative pole of the 24...
Page 36: ...d such as a relay electromagnet DC motor etc requires an external freewheeling diode Figure 4 21 Note It is strongly recommended to use protection DIODES for the inductive loads such as relays electromagnets DC motors etc Otherwise this port may damage the hardware circuit 4 6 Technical Specifications Product Features Maximum payload 5kg Weight including cable 23kg Working radius 954mm Repeatabili...
Page 37: ...rature 0 50 C IP classification IP54 Robot installation posture Install at any angle TIO Ports 2 digital input 2 digital output 1 analog input TIO Power 24V Base diameter 158mm Material Aluminum alloy PC TIO Size M8 Robot connection cable length 6m 2 Electrical cabinet technical specifications Electrical cabinet IP classification IP44 I O ports 16 digital input 16 digital output 2 analog input out...
Page 38: ...e robot system shall be considered as a new system which means that the overall safety approval process including risk assessment shall be updated accordingly 2 Replace faulty components using new components with the same article numbers or equivalent components approved by JAKA for this purpose 3 Reactivate any deactivated safety measures immediately after the work is completed 4 Document all rep...
Page 39: ... spatter ash dust cutting residue etc All Parts Main bolts All the bolts exposed on the outside of the robot need to be tightened and marked see the specified tightening torque table including the tool mounting bolts are also implemented All Parts Motor Abnormal heating or sound confirmation All Axis Brake Check when the servo power is turned ON OFF whether the robot arm or tool will fall All Axis...
Page 40: ...part or the main body which can cause the fan to malfunction or reduction of the fan s service life 5 3 Parts Replacement and Preservation When replacing the parts of the robot control unit please observe the following precautions and work safely 1 Do not carry out any modification of our products 2 Fire malfunction and wrong movements caused by modification may result in personal injury or damage...
Page 41: ...p or if any cable is caught After that reinstall the case If there is a gap it may cause dirt dust etc to enter the inside of the electrical cabinet which will cause malfunctions 5 3 1 Filter cleaning and replacement 1 Power off the electrical cabinet 2 Remove the nut from the filter housing 3 Clean the dust adhering to the filter by blowing it out Dust should be blown from the inside of the elect...
Page 42: ...the following situations it is not included in the free warranty and the user should pay for the cost of equipment JAKA should assist in troubleshooting as soon as possible to restore the equipment back to normal 1 User does not operate according to the operating procedures 2 User damages the equipment on purpose 3 Other failures caused by force majeure factors such as lightning strikes earthquake...
Page 43: ... with the user to confirm the charging method maintenance responsibility and maintenance method to ensure the performance fulfillment of maintenance responsibility III Service call hotline and contact information Email support jaka com Telephone 400 006 2665 Information required Robot serial number Software version Detailed fault description Attached log files JAKA Zu 5 ...
Page 44: ...EC 60204 1 2016 Safety of machinery Electrical equipment of machines Part 1 General requirements ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction ISO TS 15066 2016 Robots and robotic devices Collaborative robots The company s product JAKA Zu5 robot has passed CR certification and complies with the relevant requirements of CR certification standard...
Page 45: ...nts for industrial robots Part 1 Robots IEC 61000 6 2 2005 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments IEC 61000 6 4 2006 A1 2010 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments The company s product JAKA Zu5 robot has passed CR certification and meets the relevant requirements of CR ce...
Page 46: ...ts EN ISO 13849 1 2015 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 10218 1 2011 Robots and robotic devices Safety requirements for industrial robots Part 1 Robots The company s product JAKA Zu 5 robot has passed ISO 13849 1 machinery safety certification and complies with the relevant requirements of ISO 13849 1 machinery safety certifica...
Page 47: ...45 Machinery Directive 2006 42 EC EN ISO 13849 1 2015 Safety of machinery Safety related parts of control systems Part 1 General principles for design JAKA Zu 5 ...
Page 48: ...46 Machinery Directive 2006 42 EC EN ISO 10218 1 2011 Robots and robotic devices Safety requirements for industrial robots Part 1 Robots JAKAZu 5 ...
Page 49: ...dustrial environments EN 61000 6 2 2005 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments The company s product JAKA Zu5 robot has passed the EU CE EMC directive and complies with the relevant requirements of the CE EMC directive The test standards and certifications are as follows JAKA Zu 5 ...
Page 50: ...nery Electrical equipment of machines Part 1 General requirements EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction The company s product JAKA Zu 5 robot through the EU CE MD machine safety directive meets the relevant requirements of CE MD machine safety The test standards and certifications are as follows JAKAZu 5 ...
Page 51: ...ot passed the European Union RoHS 2 0 2011 65 EU and Amendment Directive EU 2015 863 and complies with the European Union RoHS 2 0 2011 65 EU and Amendment Directive EU 2015 863 The relevant requirements test standards and certifications are as follows JAKA Zu 5 ...
Page 52: ...50 7 Warranty 7 1 Product Warranty JAKAZu 5 ...
Page 53: ...ned to JAKA shall vest in JAKA The ownership of equipment or components replaced or returned to JAKA belongs to JAKA Any other claims resulting out of or in connection with the device shall be excluded from this Warranty Any other claims caused or related to equipment are not covered by the warranty Nothing in this Warranty shall attempt to limit or exclude neither a Customer s Statutory Rights no...
Page 54: ...52 Shanghai JAKA Robotics Ltd Add Building 33 35 No 610 Jianchuan Road Minhang District Tel 400 006 2665 Web www jaka com JAKAZu 5 ...
