Related Manuals for Bosch Rexroth APAS assistant K1100-10i
Summary of Contents for Bosch Rexroth APAS assistant K1100-10i
- Page 1 APAS assistant K1100-10i V01.00.00 - V01.00.99 Installation instructions Replaces: – 3 842 565 050/2019-11 ENGLISH 3 842 562 910...
- Page 2 Our products are subject to natural wear and aging. © All rights reserved by Bosch Rexroth AG, also for the registration of industrial property rights. This document may not be reproduced or distributed to third parties without our consent.
-
Page 3: Table Of Contents
EMERGENCY STOP linking between safety controller of APAS assistant and customer system controller 3.5.3 Incorporation of end effector EMERGENCY STOP into safety controller of APAS assistant 3.5.4 Trigger of stop responses 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... - Page 4 7.4.2 Acknowledging errors, acknowledging EMERGENCY STOP Diagnosis variables 7.5.1 Overview 7.5.2 Displayed statuses Parameter PROFIsafe host diagnosis code 7.6.1 States of communication with transmission 7.6.2 Error states Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11...
- Page 5 T2 operation Decommissioning Disposal Servicing and repair Maintenance instructions Maintenance of robot arm Maintenance of robot controller Maintenance of safety module Maintenance of hose breakaway device Appendix 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
-
Page 6: About This Documentation
Electrical documentation KUKA Roboter GmbH Electrical documentation of APAS assistant K1100-10i Bosch Rexroth GmbH IndraLogic XLC IndraMotion MLC 14VRS R911341695 SafeLogic system overview IH PNIOAck PSDx S20 documentation Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 7: Presentation Of Information
Indicates a hazardous situation that may result in minor to CAUTION moderate injury if not avoided. Property damage: The product or the surrounding area NOTICE could get damaged. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 8: Safety Markings
If this information is not observed, the product cannot be used and/or operated as designed. „ Single, independent action Numbered steps: The numbers indicate that the steps must be performed in order. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 9: Terms Used
Handheld programming device for KR C4. The smartPAD features all operating and display options required for the operation and programming of the industrial robot. Tool Center Point 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 10: Safety Instructions
• The product is strictly intended for professional use and not for private use. The intended use also includes having read and understood these instructions, especially section 2 "Safety instructions". Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 11: Improper Use
2.3 Improper use Any use other than that described in the section "Intended use" is considered improper and is not permitted. Bosch Rexroth AG is not liable for any damage resulting from improper use. The user alone bears any risks associated with improper use. -
Page 12: Person Commissioning The Sensor Skin
Basic course "Safe handling" [BCI-SP-AP031] Advanced course "Sensor skin maintenance" [BCI-SP-AP015] You can find an overview of the current training courses and training content online at: https://www.bosch-apas.com/downloads/. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 13: Operator
APAS assistant. These safety risks must be considered in the risk assessment for this application and mitigated by accordingly derived measures. These measures can include wearing further personal protective equipment. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 14: Integrator Responsibilities
• Ensuring that any pinching and shear points which are not addressed in the application-specific risk assessment are prevented. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 15: General Safety Instructions
T1 and T2. • Do not touch any moving parts in automatic mode and test run mode. • Do not modify or remove the protective panels. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 16: Product Description
• Protective goggles • Installation instructions • Further documentation (see Further documentation on page 6) • Packaging Should you require options after delivery, please contact Bosch Rexroth AG. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 17: Product Overview
APAS assistant can be returned to speed velocity by the customer. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 18: Safety Functions
1 with automatic restart is triggered. As soon as the trigger range of the sensor skin is free again, the robot system will restart automatically. The sensor skin requires application-specific teaching in. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 19: Discrete Emergency Stop
• suitable for PL d • PFHd ≤ 1E-7 1/h • Relays with two assigned channels on the input side, with priority-controlled, floating auxiliary contacts 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 20: Exchange Of Signals With Safety Relevance
PLC-R -> KRC Monitoring space 15 / Collaboration room PLC-R -> KRC Monitoring space 16 / Speed space PLC-R -> KRC Tool 1 Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 21: Emergency Stop Linking Between Safety Controller Of Apas Assistant And Customer System Controller
K911A EE -> PLC-R End effector emergency stop safe input channel 1 (IN-CH2) K911A PLC-R -> EE End effector emergency stop safe clock output channel 1 (CLK-CH2) 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 22: Trigger Of Stop Responses
Sensor skin is triggered STOP 1 Internal error in the analysis unit of the sensor STOP 0 skin (SSKU) Safety contact at end effector is triggered STOP 0 Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 23: Technical Data
< 57 dB (A) Requirements for the installation location see Ambient conditions on page 42 For all further technical data see the enclosed documentation of KUKA Roboter GmbH. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 24: Work Area And Permissible Velocity
With sensor head option 28.5 ms ± 1 ms With KEE option 30 ms ± 1.5 ms With max. upgrade (192 sensor elements) 47.5 ms ± 2.5 ms Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 25: Bearing Load
1180.196 kg mm² Moment of inertia I · 17.386 kg mm² Moment of inertia I · 4.014 kg mm² · Moment of inertia I 1424.264 kg mm² 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 26: Effective Range Of The Sensor Skin
Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 27: Robot Controller Data
-25 °C to +70 °C Requirements for the installation location see Ambient conditions on page 42 For further technical data see the vendor documentation of KUKA Roboter GmbH. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 28: Safety Module Data
-40 °C to +70 °C Installation position Upright installation only see Installing the safety module on page 46). Requirements for the installation location see Ambient conditions on page 42 Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 29: Pneumatics And Hose Breakaway Device
U.I. Lapp GmbH 3 x ø 4 mm 53320340 U.I. Lapp GmbH 4 x ø 4 mm 53320440 U.I. Lapp GmbH 2 x ø 6 mm 53320260 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 30: Connecting Cables
Ring terminal on robot controller M4 and customer potential equalizer Customer potential equalizer bar I/O cable for options between robot Robot arm X909 arm base and customer Open cable end Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 31: Bus Topology Profinet/Profisafe
APAS assistant PROFIsafe PROFIsafe Steuerung/ Bus coupler with Buskoppler mit controller / Sicherheits- safety cards Sicherheitskarten safety controller steuerung Controller in PLC-R Device in PLC-R Device in KRC 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 32: Preconfigured Workvisual Project
The rotational speed stop must not be disabled! General Cartesian velocity monitoring is required for the collaborative velocity monitoring and must be enabled. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... - Page 33 The settings must be between the following limits: Axis Lower limit Upper limit -170° 170° -165° 25° -45° 135° -185° 185° -90° 100° -185° 185° 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
- Page 34 Axis monitoring The axis monitoring must be considered by the system integrator in the risk assessment. The values in the settings must be within the determined limits. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11...
- Page 35 Tools 2-16 are at the free disposal of the system integrator. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
-
Page 36: End Effector
The following option packages must have been placed in the WorkVisual project for operation of the APAS assistant: • Diagnosis Safety • KUKA.PROFINET MS • LoadDataDetermination • SafeOperation Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 37: Signals For Signal Lamp
OUT4117 apas_CustPLC_Out2 Customer PLC-R digital output 2 KRC -> PLC-R OUT4118 apas_CustPLC_Out3 Customer PLC-R digital output 3 KRC -> PLC-R OUT4119 apas_CustPLC_Out4 Customer PLC-R digital output 4 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 38: Transport And Storage
(see Transporting the product on page 38). 5.1 Transporting the product Bosch Rexroth AG is not liable for any damage caused by improper transport of the products. The transport crate may only be unloaded and transported by a specialist company or by trained personnel instructed on the safety technology. -
Page 39: Transporting The Robot Arm
• The robot arm is secured by the transport gear until it is securely fastened at the installation location. Specification of the transport gear Description Specification Crane, lifting gear and shackles Load-bearing capacity > 100 kg Rope length min. 1,500 mm 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 40: Transporting The Robot Controller
Lift the load carefully and watch if there is a risk that the load may tip. Move the robot arm to the corresponding installation location. 5.1.3 Transporting the robot controller Observe the vendor documentation of KUKA Roboter GmbH. „ Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 41: Storing The Product
The product must be stored, packaged and transported in such a way that no additional pressure is applied to the product (e.g. when stacked). „ The product must not be exposed to any impact during storage or transport. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 42: Assembly And Installation
Wear the required personal protective equipment during installation to minimize any hazards. The following must be worn during all work: - protective clothing - protective footwear Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 43: Installing The Robot Arm
– The drill holes for fastening of the robot arm have been prepared. The robot can be fastened on a foundation or a machine frame. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 44: Installing The Hose Breakaway Device
Place the hose mounting clip on the profiled joint (1) at an angle at snap the clip into place with a rotary movement (2). Repeat the previous step to fasten the hose mounting clips in all six positions. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... - Page 45 Make sure that the pneumatic lines do not rub against the sensor skin or other components. Adapt the placement of the pneumatic lines if necessary. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
-
Page 46: Installing The Safety Module
(2) in the rotary union. Fasten the clamp ring in position (3) with two screws M4x16-8.8 (3.3 Nm) around the end effector on the rotor. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 47: Electrical Interfaces
• Running in and/or out of cable baskets or cable drums • Acceleration forces and wind forces for cable festoon systems or free-hanging cables • Excessive friction by cable pickups • Impact of excessive radiant heat 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 48: Commissioning
Observe the information in the vendor documentation installation and operating instructions KUKA.SafeOperation 3.4 V6 of KUKA Roboter GmbH. Perform adjustment referencing of the axes one to five. „ Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 49: Operation Without Higher-Level Controller
Connect the signals for $DRIVES_ON, $CONF_MESS, $EXT_START in the I/O „ circuitry with the inputs of the PROFINET master (PLC within the SafetyBox). Signal Connection with $OUT[4106] b_Kuka_EXT_START_i $OUT[4107] b_Kuka_CONF_MESS_i $OUT[4108] b_Kuka_DRIVES_ON_i 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 50: Preparing The Program
• Adjustment referencing performed or integrated into program Procedure Select the prepared program in the navigator. Carry out the SAK run. Switch to Automatic-External operating mode. The robot starts the programmed movement. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 51: Operation With Higher-Level Controller
• $PERI RDY: Drives are not ready Acknowledge message • $CONF_MESS: Acknowledge message Acknowledgeable messages have been deleted • $STOPMESS is no longer active, the signal $CONF_MESS is canceled 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... - Page 52 $DRIVES_ON, $CONF_MESS and $EXT_START into the system controller. These are connected with the safety module in the I/O circuitry of the KR C4 controller. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11...
-
Page 53: Acknowledging Errors, Acknowledging Emergency Stop
For this reason, the same signal can be linked with the input to the acknowledgment edge of all FB instances in order to implement an unspecific confirmation of communication problems. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 54: Diagnosis Variables
IN4188-IN4203 apas_Diag_KUKA_DC APAS diagnosis signal for the safety card in the KRC PLC-R -> KRC IN4188-IN4203 apas_Diag_KUKA_DC APAS diagnosis signal for the safety card in the KRC Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 55: Displayed Statuses
The diagnosis variable of the type BYTE indicates the channel reporting the diagnosis of apas_Diag_SafetyIoNo. Value State/device Channel 1 Channel 2 The entire module is affected. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... - Page 56 The F-device requires a confirmation by the operator TRUE (apas_Diag_QuitErrorBus) to resume the safety function. FALSE The F-device does not currently require any confirmation by the operator (apas_Diag_QuitErrorBus). Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11...
- Page 57 Waits until program is selected and running (e.g. R1/PRG.SRC). Permanent query whether sensor skin has been triggered or EMERGENCY STOP is active. Query whether sensor skin has been triggered. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
-
Page 58: Parameter Profisafe Host Diagnosis Code
Invalid length of the I/O telegrams (4 <= telegram length <= 12) 16#C030 The underlying I/O system could not be initialized. An internal error has occurred in the configuration data. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 59: Operation
This can be done with a separate home position run in T1 operation or at the start of an automatic sequence. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 60: T1 Operation
Return any potentially harmful substances, such as lubricants or batteries, to the „ appropriate disposal point. „ Completely remove oils and other substances hazardous to water prior to any dismantling for recycling or scrapping. Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 61: Servicing And Repair
(EMERGENCY STOP and safe stop) are functional. When using fastening on Observe the vendor documentation of Yearly „ foundation: Verify the KUKA Roboter GmbH. torque of the four fastening screws. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 62: Maintenance Of Robot Controller
Replace control PC fan. Every five years (in case of 3-shift operation) Replace exterior fan. Every five years (in case of 3-shift operation) Replace batteries. Depending on battery monitor display Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... -
Page 63: Maintenance Of Safety Module
Moist cleaning cloth and mild cleaning agents or As needed breakaway device aspirated air. Observe the safety measures. „ „ Define a maintenance interval for cleaning depending on the application. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG... -
Page 64: Appendix
OUT0 • Check if an error (channel 1 or channel 2) is detected (see further documentation IndraControl S20 Module with secure digital outputs S20-PSDO-8/3 (R911369166)). Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11... - Page 65 EMERGENCY STOP NHE (input byte 0, bit 1)) Check if an error (channel 1 or channel 2) is detected (see application description IndraControl S20 Module with secure digital inputs S20-PSDI-8/4 (R911369170)). 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
- Page 66 Check if collaboration room in the safety configuration is "always active" (max. velocity 500 mm/sec). Check if collaboration room in the safety configuration is "always active" (max. velocity 500 mm/sec). Bosch Rexroth AG, APAS assistant K1100-10i V01.00.00 - V01.00.99, 3 842 565 050/2019-11...
- Page 67 Confirmation of compliance with the above requirements: Date: Validator: Signature: Any deviations from the requirements and the necessary measures must be stated in the "Comment" column or in additional appendices to this document. 3 842 565 050/2019-11 APAS assistant K1100-10i V01.00.00 - V01.00.99, Bosch Rexroth AG...
- Page 68 Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax +49 711 811–7777 info@boschrexroth.de www.boschrexroth.com Subject to modifications 3 842 565 050/2019-11...