Techman Robot Safety System 3.3 Instruction Manual

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Safety Manual

Original Instruction

1648-E-04

TECHMAN ROBOT Safety System 3.3

Safety Manual TECHMAN ROBOT Safety System 3.3 i

This Manual contains information of the Techman Robot product series (hereinafter referred to as the TM Robot). The

information contained herein is the property of Techman Robot Inc. (hereinafter referred to as the Corporation) and

shall not be reproduced in whole or in part without prior authorization from the Corporation. No information contained

herein shall be considered an offer or commitment. The information herein is subject to change without notice. The

document is periodically reviewed and revised. The Corporation assumes no responsibility for any errors or omissions

in the documentation.

logo is registered trademark of TECHMAN ROBOT INC. in Taiwan and other countries and the company

reserves the ownership of this manual and its copy and its copyrights.

Safety Manual TECHMAN ROBOT Safety System 3.3 2

Terms and Conditions Agreement

Warranty Limitations of Liability

Warranties

 Exclusive Warranty

Omron’s exclusive warranty is that the Products will be free from defects in materials and workmanship for a

period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron).

Omron disclaims all other warranties, express or implied.

 Limitations

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT

NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF

THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE

PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.

Omron further disclaims all warranties and responsibility of any type for claims or expenses based

on infringement by the Products or otherwise of any intellectual property right.

 Buyer Remedy

Omron’s sole obligation hereunder shall be, at Omron’s election, to (i) replace (in the form originally shipped

with Buyer responsible for labor charges for removal or replacement thereof) the non-complying Product, (ii)

repair the non-complying Product, or (iii) repay or credit Buyer an amount equal to the purchase price of the

non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity

or any other claims or expenses regarding the Products unless Omron’s analysis confirms that the Products

were properly handled, stored, installed and maintained and not subject to contamination, abuse, misuse or

inappropriate modification. Return of any Products by Buyer must be approved in writing by Omron before

shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the use of

Products in combination with any electrical or electronic components, circuits, system assemblies or any

other materials or substances or environments. Any advice, recommendations or information given orally or in

writing, are not to be construed as an amendment or addition to the above warranty.

See http://www.omron.com/global/ or contact your Omron representative for published information.

Safety Manual TECHMAN ROBOT Safety System 3.3 3

Limitation of Liability; Etc

OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR

CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY

WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT,

WARRANTY, NEGLIGENCE OR STRICT LIABILITY.

Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which

liability is asserted.

Application Considerations

Suitability of Use

Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply

to the combination of the Product in the Buyer’s application or use of the Product. At Buyer’s request, Omron

will provide applicable third party certification documents identifying ratings and limitations of use which apply to

the Product. This information by itself is not sufficient for a complete determination of the suitability of the

Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely

responsible for determining appropriateness of the particular Product with respect to Buyer’s application,

product or system. Buyer shall take application responsibility in all cases.

NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR

PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO

ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND

INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

Programmable Products

Omron Companies shall not be responsible for the user’s programming of a programmable Product, or any

consequence thereof.

Disclaimers

Performance Data

Data presented in Omron Company websites, catalogs and other materials is provided as a guide for the user

in determining suitability and does not constitute a warranty. It may represent the result of Omron’s test

conditions and the user must correlate it to actual application requirements. Actual performance is subject to

the Omron’s Warranty and Limitations of Liability.

Safety Manual TECHMAN ROBOT Safety System 3.3 4

Change in Specifications

Product specifications and accessories may be changed at any time based on improvements and other

reasons. It is our practice to change part numbers when published ratings or features are changed, or when

significant construction changes are made. However, some specifications of the Product may be changed

without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications

for your application. Please consult with your Omron representative at any time to confirm actual specifications

of purchased Product.

Errors and Omissions

Information presented by Omron Companies has been checked and is believed to be accurate; however, no

responsibility is assumed for clerical, typographical or proofreading errors or omissions.

Safety Manual TECHMAN ROBOT Safety System 3.3 5

Revision History Table ....................................................................................................................................................... 9

1. Comprehensive Information ........................................................................................................................................ 10

Overview ............................................................................................................................................................ 10

Applicable Product Version ................................................................................................................................ 10

Safety Warning Symbols .................................................................................................................................... 10

Safety Precautions ............................................................................................................................................. 11

Validation and Responsibility ............................................................................................................................. 12

Limitation of Liability ........................................................................................................................................... 12

Overall Safety Warning ...................................................................................................................................... 12

Intended Use ...................................................................................................................................................... 14

Risk Assessment ................................................................................................................................................ 15

2. Safety Function ........................................................................................................................................................... 17

2.1 Overview ............................................................................................................................................................ 17

2.2 General Information ........................................................................................................................................... 17

2.2.1 Safety Function Definitions ......................................................................................................................... 17

2.2.2 Stopping Time and Stopping Distance in the Safety System ...................................................................... 18

2.2.3 Software Safety Setting Permissions .......................................................................................................... 18

2.3 Explanation of Safety Functions ........................................................................................................................ 18

2.3.1 SF0 Robot Stick ESTOP and SF1 User Connected ESTOP Input ............................................................. 18

2.3.2 SF2 Encoder Standstill ................................................................................................................................ 20

2.3.3 SF3 User Connected External Safeguard Input and SF9 User Connected External Safeguard Input for

Human-Machine Safety Settings .......................................................................................................................... 20

2.3.4 SF4~SF8 Defined Safety Functions ............................................................................................................ 21

2.3.5 SF10~SF14 Safety Output Functions ......................................................................................................... 24

2.3.6 SF15 and SF16 Safety Input Functions ...................................................................................................... 27

2.3.7 SF17 Cartesian Limit A ............................................................................................................................... 29

2.3.8 SF18 Cartesian Limit B ............................................................................................................................... 29

2.3.9 Safety Checksum ........................................................................................................................................ 30

3. Safety Related Operation ............................................................................................................................................ 31

Safety Manual TECHMAN ROBOT Safety System 3.3 6

Joint Movement without Drive Power ................................................................................................................ 31

During an Emergency Stop Procedure ....................................................................................................... 31

Extending the Robot from the Packing Pose .............................................................................................. 31

Power Loss .................................................................................................................................................. 31

Operation Mode and Mode Switching ................................................................................................................ 32

Auto Mode ................................................................................................................................................... 32

Manual Mode ............................................................................................................................................... 32

Switch Between Modes ............................................................................................................................... 33

Hold to Run ........................................................................................................................................................ 33

Singularity Point ................................................................................................................................................. 34

Replacing the Robot Stick in Local Control ....................................................................................................... 39

4. Compliance of Safety Regulations .............................................................................................................................. 40

Compliance ........................................................................................................................................................ 40

Requirement of Enabling Device ................................................................................................................. 40

Access of Safety Setting ............................................................................................................................. 40

5. Declaration of Incorporation ........................................................................................................................................ 41

Appendix A. Certificate of Compliance and Declaration of Incorporation ....................................................................... 44

Appendix B. Verifications of EMC Compliance ............................................................................................................... 48

Appendix C. TM Robot Stopping Time and Distance for all Series Product Models ...................................................... 50

Tables

Table 1: Safety System Version ........................................................................................................................ 10

Table 2: Safety Warning Symbols ..................................................................................................................... 11

Table 3: Safety Function Definitions ................................................................................................................. 17

Table 4: Stop Category and Action of Fault Detection of SF0 and SF1 ........................................................... 19

Table 5: Stop Category and Action of Fault Detection of SF3 and SF9 ........................................................... 21

Table 6: SF4~SF8 Defined Safety Functions ................................................................................................... 22

Table 7: Stop Category and Reaction of Fault Detection of SF4~SF8 ............................................................. 22

Table 8: Output Signal and Action of Fault Detection of SF10~SF14 ............................................................... 26

Table 9: Application example of Safety Output Function .................................................................................. 27

Table 10: Stop Category and Reaction of Fault Detection of SF15 and SF16 ................................................. 28

Table 11: Stop Category and Reaction of Fault Detection of SF17 .................................................................. 29

Table 12: Stop Category and Reaction of Fault Detection of SF18 .................................................................. 30

Table 13: The R

Table 14: Control Methods in Respective Modes Summary ............................................................................. 39

values of each product series ........................................................................................... 34

offset

Table 15: Declaration of Incorporation .............................................................................................................. 43

Table 16: Stopping Time and Distance for TM5-700 Series ............................................................................. 50

Table 17: Stopping Time and Distance for TM5-900 Series ............................................................................. 51

Table 18: Stopping Time and Distance for TM14 Series .................................................................................. 52

Table 19: Stopping Time and Distance for TM12 Series .................................................................................. 53

Figures

Figure 1: X, Y, & Z axes .................................................................................................................................... 24

Safety Manual TECHMAN ROBOT Safety System 3.3 7

Figure 2: Checksum .......................................................................................................................................... 30

Figure 3: The Definition of R

. ...................................................................................................................... 35

offset

Figure 4: Extensible Singularity Point in Space ................................................................................................ 36

Figure 5: Wrist Singularity Point in Space ........................................................................................................ 36

Figure 6: The Solution when Encountering Singularity Point in Space (1/2) .................................................... 37

Figure 7: The Solution when Encountering Singularity Point in Space (2/2) .................................................... 38

Safety Manual TECHMAN ROBOT Safety System 3.3 8

Revision History Table

Revision Date Revised Content

01 December 2019 Original release

02 January 2020 Updated Appendix A

03 April 2020 Updated Chapter 4.1.2

August 2020

Updated info on Safety System 3.3 and Appendix A

Safety Manual TECHMAN ROBOT Safety System 3.3 9

1. Comprehensive Information

Overview

This chapter describes the comprehensive important safety information of TM Robot. The user and system

integrator of TM Robot must read and fully understand this chapter before using this robot.

Applicable Product Version

This document is only applicable to the combination of the following software and hardware versions of TM Robot.

Users can check the hardware version and software version on “Techman Robot Product Brief Information” sheet

in the control box carton, or through these methods: checking the hardware version on the product label on the

control box and checking the software version from the software information button in the UI of TMflow. If the

software version of the robot has been upgraded and is different from the original out-of-the-box one, users should

only check the software version from the UI of TMflow.

Safety System version: TECHMAN ROBOT Safety System 3.3*

Hardware version

Software version

*Within the scope of hardware and software combination above, the safety system version remains the same as TECHMAN ROBOT Safety System 3.3

HW 3.2

SW 1.80

Table 1: Safety System Version

Users shall confirm whether the software and hardware version of the TM Robot is consistent with the applicable

product version of this Safety Manual. The Corporation is not responsible for any safety issues caused by referring

to the safety instruction of an incorrect version.

Safety Warning Symbols

The following table defines the levels of the safety warning symbols that are marked in each paragraph in this

Manual. Read carefully and comply with each paragraph to avoid harm to people or equipment.

DANGER:

Identifies an imminently hazardous situation which, if not avoided, is likely to result in serious

injury, and might result in death or severe property damage.

WARNING:

Identifies a potentially hazardous situation which, if not avoided, will result in minor or moderate

injury, and might result in serious injury, death, or significant property damage.

CAUTION:

Identifies a potentially hazardous situation which, if not avoided, might result in minor injury,

moderate injury, or property damage.

Safety Manual TECHMAN ROBOT Safety System 3.3 10

Read Manual and Impact Warning labels

WARNING: ELECTROCUTION RISK

Identifies a hazardous electrical situation.

Table 2: Safety Warning Symbols

Safety Precautions

DANGER:

This product can cause serious injury or death, or damage to itself and other equipment, if the

following safety precautions are not observed.

 All personnel who install, operate, teach, program, or maintain the system must read the Hardware

Installation Manual, Software Manual, and Safety Manual according to the software and hardware version of

this product, and complete a training course for their responsibilities concerning the robot.

 All personnel who design the robot system must read the Hardware Installation Manual, Software Manual,

and Safety Manual according to the software and hardware version of this product, and must comply with all

local and national safety regulations of the location where the robot is installed.

 Observe the “Intended Use” section in Safety Manual.

 If the installation and application does not observe human-robot collaboration regulations of the safety

regulations, the user is responsible for providing safety barriers around the robot to prevent anyone from

accidentally coming into contact with the robot when it is in motion.

 If any local or national electrical regulation requires, power to the robot and its power supply must be locked

out and tagged out, or have means to control hazardous energy or implement energy isolation before any

maintenance is performed.

 Dispose of the product in accordance with the relevant rules and regulations of the country or area where

the product is used.

Safety Manual TECHMAN ROBOT Safety System 3.3 11

countries and prevent major hazards from occurring in the complete system.

Validation and Responsibility

The information provided in this Manual does not include how to design, install and operate a complete arm

application, nor does it include the peripheral devices that will affect the overall system safety. The design and

installation of the complete system must comply with the standards and regulations for safety requirements in the

country located. The robot integrator needs to understand safety laws and safety regulations in the local countries,

in order to avoid major risks existing in the entire system.

This includes but is not limited to:

 Performing a risk assessment of the whole system

 Adding other machines and additional risk reduction measures based on the results of the risk assessment

 Using appropriate software safety features

 Ensuring the user will not modify any safety measures

 Ensuring all systems are correctly designed and installed

 Specifying instructions for use

 Clearly marking the contact information of the integrator that installed the robot

 Making relevant documents accessible, including the risk assessment, and this manual

CAUTION:

This product is partly completed machinery. The design and installation of the complete

system must comply with the safety standards and regulations in the country of use. The user

and integrators of the robot should understand the safety laws and regulations in their

Limitation of Liability

Even if the safety instructions are followed, any safety-related information in the manual shall not be considered as

a guarantee that the product will not cause any personal injury or damage.

Overall Safety Warning

These safety warnings are relevant for the entire manual.

Safety Manual TECHMAN ROBOT Safety System 3.3 12

DANGER:

1. Before transporting, installing, operating, maintaining and repairing this product, make sure to read the product

specification and operation manual in detail. Confirm that all the conditions comply with the requirements of the

specification and the Manual, to avoid unintended accidents (for example: improper operation or conditions of

use that exceed the product specification) that may result in injury to personnel.

2. Before installing and using this product, the integrator must perform a risk assessment and implement risk

reduction measures.

3. Users shall create procedures for emergency and abnormal situations.

4. Before using this product, make sure that the emergency stop device functions correctly.

WARNING:

1. Before disassembling or repairing this product, make sure that the power has been turned off and disconnected

before proceeding to avoid injury to people or damage to machinery caused by inadvertent short circuit or

electric shock.

2. When operating this product, the operator shall avoid wearing loose clothing or wearing other accessories (such

as: necklaces, ties, bracelets, etc.) to avoid injury caused by clothing or accessories becoming entangled in the

machine during operation.

3. If the product malfunctions, follow the established procedures of your organization to obtain repair of the product.

Do not attempt to repair the product yourself to avoid damage to the machinery.

4. Before the robot is in operation, make sure that each part has been completely mounted to avoid any possibility

of accidents.

5. Before starting the operation of the robot, confirm that there are no persons or obstacles that may intrude into

the operating area during operation. If the operating environment uses human-robot cooperative operation, be

sure to complete the due risk assessment before starting the operation.

6. It is forbidden for any unauthorized person to operate this product in order to avoid any possibility of injury to

personnel or damage to the machinery.

7. Do not install or operate this product in a hazardous area (for example: strong magnetic field, hazardous gas,

fire source, or flammable product) In order to prevent the machinery from causing danger during operation

because of external conditions.

Safety Manual TECHMAN ROBOT Safety System 3.3 13

CAUTION:

1. Before operating the robot, confirm the status of the machinery warning light.

2. After editing the task flow, operate the robot in the Manual Mode first, and confirm that all the movements in the

task flow are correct before switching the operation mode to Auto Mode.

3. During the operation of machinery, do not turn off the power supply to prevent possible damage to the system.

4. For the robot noise levels and related environmental conditions, refer to the Hardware Installation Manual for the

corresponding hardware version.

Intended Use

The TM Robot is designed so the hazards can be reduced to tolerable levels when installed as specified and

operated under normal and intended use.TM Robots have been designed and constructed in accordance with

relevant safety standards. TM Robots are intended for use in parts assembly and material handling for payloads

(including end-effector and workpiece) up to the “Maximum Payload” specification of each model.

The TM Robot focuses on the safety of human-robot cooperative operation by design, but the cooperative

operation is only for application procedures that have undergone a risk assessment including robots, related

peripheral equipment and working environment.

Any use or application should consider the risk assessment. If the use is different from the intended application,

The Corporation will not bear any responsibility. The Corporation clearly specifies that the following uses are not

suitable for the TM Robot. This is not a complete list.

• Use in a potentially hazardous environment

• Use in any applications that may threaten human lives

• Use in any application that may cause personal injuries

• Use before completion of the risk assessment and implementation of risk reduction measures

• Use for life support

• Use when the rated performance cannot be reached

• Use when the reaction time of safety functions is insufficient

• Use without appropriate parameters in operations

• Use in applications which may cause damage to the robot itself

• Restricted movement of persons

• Use without proper mounting of the robot

• Use involving excessive oscillations when moving

• Use without proper design of earthquake-prevention mounting when installed in earthquake zones

Safety Manual TECHMAN ROBOT Safety System 3.3 14

• Use without safe access to (or at/from) the work station

• Use in the presence of exhaust gases/lack of oxygen at the work position

• Use in the presence of flame (flammability of the cabinet, lack of extinguishing means)

• Use with mechanical hazards at the work position: a) rollover; b) fall of objects, penetration by objects; c)

break-up of parts moving at high speed; d) contact of persons with machine parts or tools (non-collaborative

machines)

• Use with insufficient visibility from the work positions

• Use with inadequate lighting

• Use with inadequate seating

• Use with insufficient means for escape or entrapment avoidance

• Use with inadequate location of manual controls

• Use with inadequate design of manual controls and their mode of operation

Risk Assessment

Before installing and using this product, the user must first perform a risk assessments based on the conditions of

use. Risk assessments can be in reference to the specifications of ISO 10218-2, ISO 12100 and ISO/TS 15066

documentations. The purpose of a risk assessment is to anticipate any accidents that may occur during the

operation process and by means of appropriate protective measures to reduce the occurrence of accidents or to

reduce the severity of injury to persons in the event of an accident. Therefore, the risk assessment needs to include

any operational actions of the machinery within the scope of the assessment. After the risk assessment is

completed, the user can use external related components (i.e. sensing components, emergency stop devices,

fences or railings, etc.) as well as the parameter settings of safety functions in the operating system, to reduce

possible occurrence of accidents. Additional safety-related components must be installed in accordance with the

manufacturer's specifications for the required risk reduction. For operating system safety settings and other safety

components usage, read and understand this manual, the Software Manual and the Hardware Installation Manual

of corresponding versions.

Potential hazards requiring additional risk reduction measures may include but are not limited to:

1. Finger(s) (especially in the case of hand guiding) caught between the rear end of the camera module and the

joint module(s).

2. The palm or finger injured by the motion of the robot or the hand guide teaching, if caught between the robot

end-effector (including the workpiece) and the robot body.

3. Being hit by a robot and injured.

4. Entrapment between a robot and a fixed surface.

5. Incorrect human-robot collaborative workspace setup, parameter settings or project operation.

6. TCP force may be estimated incorrectly when robot is passing the area near singularity point in space, due to

Safety Manual TECHMAN ROBOT Safety System 3.3 15

operation of the robot system.

situations.

the nature of singularity.

WARNING:

Ensure compliance with all local and national safety and electrical codes for the installation and

WARNING:

Provide appropriately sized Branch Circuit Protection and Lockout/Tagout Capability in

accordance with the National Electrical Code and any local codes.

WARNING: ELECTROCUTION RISK

It is necessary for a skilled and instructed person to perform AC power installation. During

installation, it is mandatory to prevent unauthorized third parties from turning on power with the

use of lockout/tagout measures.

Failure to use appropriate power can lead to malfunction or failures of the robot or hazardous

Safety Manual TECHMAN ROBOT Safety System 3.3 16

Number

SF0

Robot Stick ESTOP

Emergency Stop

Cat. 3 d SF1

User Connected ESTOP Input

Emergency Stop

Cat. 3

Human-Machine Safety Settings

ESTOP Output

2. Safety Function

2.1 Overview

TM Robot incorporates multiple safety functions, and provides interfaces for additional external protective devices.

2.2 General Information

The following describes common information of the TM Robot system safety functions:

2.2.1 Safety Function Definitions

Safety Function Definitions of TM Robot System are listed in the following table:

Safety

Function

SF2

SF3

SF4

SF5

SF6

SF7

SF8

SF9

SF10

SF11

Name

Encoder Standstill

User Connected External Safeguard Input

Joint Torque Monitoring

Joint Position Limit

Joint Speed Limit

TCP Speed Limit

TCP Force Limit

User Connected External Safeguard Input for

Robot ESTOP Output

User Connected External Safeguard Output

Robot Stopping

Function

Protective Stop

Structure

Category

Cat. 2 d

Cat. 3 d

SF12

SF13

SF14

SF15

SF16

SF17

SF18

User Connected External Safeguard Output for

Robot Internal Protective Stop Output

Robot Moving Output

User Connected Enabling Device Input

User Connected ESTOP Input without Robot

Cartesian Limit A

Cartesian Limit B

Protective Stop

Emergency Stop

Protective Stop

Cat. 3 d

Cat. 2 d

Cat. 3 d

Cat. 2 d

Table 3: Safety Function Definitions

Note:

1. The structure category according to ISO 13849-1:2015.

2. PL (Performance Level) in accordance with ISO 13849-1:2015.

3. Emergency stop and protective stop in accordance with ISO 10218-1:2011.

4. Stop categories in accordance with IEC 60204-1.

Safety Manual TECHMAN ROBOT Safety System 3.3 17

2.2.2 Stopping Time and Stopping Distance in the Safety System

Safe stopping time is the time required from when an emergency stop or protective device (i.e. internal or

external) is activated and motion stops. In this system, activating the emergency stop button will apply Cat.

1 safety stop. Activation of a safety function or external safety protective device will be a Cat. 2 stop. It may

be necessary for the user or the system integrator to take these stop times into consideration when

implementing risk reduction measures. The robot continues moving during this time, which can transmit

energy and present additional risk. Refer to Appendix C for stopping time and stopping distance.

2.2.3 Software Safety Setting Permissions

A change management process should be in place listing known acceptable settings and potential hazards.

Changes are made in the permissions management function. The authorized user must log in with

administrator’s privilege to set all levels of permissions appropriately. Cybersecurity measure should take

place when using a network connection. The Corporation is not liable for the possible harm caused by

malicious attacks or intrusion of the users’ network to modify the permissions management system or

safety setup.

2.3 Explanation of Safety Functions

2.3.1 SF0 Robot Stick ESTOP and SF1 User Connected ESTOP Input

The SF0 Robot Stick ESTOP refers to the built-in Emergency Switch on the Robot Stick of the TM Robot

control box, and the SF1 User Connected ESTOP Input refers to the Emergency Stop Port on the control

box, which is applicable to connect additional emergency switches.

Refer to the table below for the stop category and the reaction of the fault detection of the safety functions.

The functions come with discrepancy detection to maintain safety when detecting conflicting signals from

the dual channel input. When a discrepancy occurs, the system will enter and lock in a safety status. To

resume from the safety status, first check the input wiring, correct it, and let the dual inputs open and close

again, to enable the robot to the resume status of the safety function. When any fault other than

discrepancy in the safety functions is detected, the system performs a Cat. 0 stop. When Cat. 0 stop occurs,

reboot the robot system to recover from Cat.0 stop status.

Safety Manual TECHMAN ROBOT Safety System 3.3 18

Number

Others: Cat. 0 stop

ESTOP Input

Others: Cat. 0 stop

operator or collide with other objects.

Safety

Function

Name

Stop

Category

Action of

Fault Detection

SF0 Robot Stick ESTOP Cat. 1 stop

SF1

Note: Stop categories in accordance with IEC 60204-1.

User Connected

Cat. 1 stop

Discrepancy: Cat.1 Stop

Table 4: Stop Category and Action of Fault Detection of SF0 and SF1

The user can stop movement by pressing the Emergency Stop button. After the movement of the robot has

ceased, the user must confirm that no hazardous conditions are present before manually releasing the

Emergency Stop button to allow reactivation of the robot. The Emergency Stop should be used only when a

critical condition occurs. To stop the movement of the robot under normal operation, use the Stop Button on

the Robot Stick.

If the risk assessment requires additional Emergency Stop devices, the selected device must comply with

the requirements of the IEC 60204-1. Any additional Emergency Stop Devices must be connected to the

User Connected ESTOP Input port (SF1), so they do not diminish the overall performance level of the

Emergency Stop.

Activation of an emergency stop initiates a Cat. 1 stop. The Indication Light Ring of the robot will not display

light and the three lights on the Robot Stick will be constantly blinking. The steps to reset the emergency

stop are as follows:

1. Rotate the Emergency Switch to the pop-up state. At this time, the robot arm will be re-powered. The

Indication Light Ring will have the light blue light on to indicate the Safe Start up Mode.

2. Press the Stop Button on the Robot Stick for about three seconds. The robot will perform the calibration

action of the start-up process and return to the previous operating mode.

WARNING:

The power of the robot arm will be cut and the joint brake will be activated, if the Emergency

Stop is triggered. The Indication Light Ring of robot’s end module will not show light and the

three lights from the robot stick will be constantly blinking. In this case, although each of the

joints will be automatically locked by their brakes, the robot body will still drop slightly, before it

completely stops. Pay attention to the risk that the end part of the robot may pinch the

Safety Manual TECHMAN ROBOT Safety System 3.3 19

workpiece to be dropped.

Clear off the loading at the tool end before recovering from the emergency stop.

calibration motion.

WARNING:

During an Emergency Stop, power to the end effector will be cut. If the system was integrated

with a power I/O enabled end effector, the emergency stop condition may cause the

CAUTION:

Personnel should be outside of the robot’s operational space (areas that robot can reach)

when recovering from the emergency stop.

CAUTION:

During the Joint Position Calibration period, each joint of the robot will perform a calibration

motion. Make sure the robot pose is in a clear space of at least 5 degrees per joint to perform

the calibration motion before starting the calibration. At the same time, make sure the TCP,

which may have a long distance to the robot flange, will not causing harm during the

2.3.2 SF2 Encoder Standstill

This safety function is automatically activated after every Cat. 2 Stop. Encoders of each joint are monitored

continuously to check if there is any unintended motion until the user acknowledges and manually resets

the robot from the state of Cat. 2 Stop. If there is any unintended motion, this safety function will trigger a

Cat. 0 Stop. When any fault other than discrepancy is detected in the safety function, the system performs

a Cat. 0 stop. When a Cat. 0 stop occurs, reboot the robot system to recover from Cat. 0 stop status.

2.3.3 SF3 User Connected External Safeguard Input and SF9 User Connected External Safeguard Input for

Human-Machine Safety Settings

These two safety inputs are present on the Safeguard Port of the robot control box. For the related

connection and usage, refer to the Hardware Installation Manual. Resuming from the SF3 User Connected

External Safeguard Input protective stop and SF9 User Connected External Safeguard Input for

Human-Machine Safety Settings can be manual or auto. If manual resume is configured, press the PL AY

button to resume the original status. For the setting for manual or automatic resume, refer to the relevant

contents in the Software Manual.

Refer to the table below for the stop category and the reaction of fault detection of the safety functions. The

functions come with discrepancy detection to maintain the safety status when detecting conflicting signals

from a dual channel input. When a discrepancy occurs, the system will enter and lock in a safety status of

Cat. 1 stop. To resume from the safety status, first check the input wiring, correct it, and follow the steps

below to resume.

1. Let the dual inputs open and close again. At this time, the robot arm will be re-powered. The Indication

Safety Manual TECHMAN ROBOT Safety System 3.3 20

Number

Others: Cat. 0 stop

for Human-Machine Safety Settings

Others: Cat. 0 stop

Light Ring will have the light blue light on to indicate the Safe Start up mode.

2. Press the Stop Button on the stick for about three seconds. The robot will perform the calibration

action of the start-up process and return to the previous operating mode.

When any fault other than discrepancy detected in the safety functions, the system performs a Cat. 0 stop.

When Cat. 0 stop occurs, reboot the robot system to recover from Cat.0 stop status.

Safety

Function

Name

SF3 User Connected External Safeguard Input Cat. 2 stop

SF9

Note: Stop categories in accordance with IEC 60204-1.

User Connected External Safeguard Input

Stop

Category

Reaction of

Fault Detection

Discrepancy: Cat. 1 Stop

Table 5: Stop Category and Action of Fault Detection of SF3 and SF9

SF9 is a function to decrease the robot speed to which is set in Human-Machine Safety Settings and comes

with a deceleration time parameter that users can configure to prevent force/torque related safety functions

from triggering by the dramatic slowdown from high speed. The upper limit of the deceleration time is 800

milliseconds. Note that there is a fixed time delay of 1122 milliseconds after the trigger of Human-Machine

Safety Settings to start to monitor the TCP speed to let the robot decrease to speed from Human-Machine

Safety Settings. Users should take these timings into considerations for the risk assessment of applications

and set the distance of the safeguard properly.

2.3.4 SF4~SF8 Defined Safety Functions

The name and description of SF4 to SF8 safety functions are listed in the following table:

Safety Manual TECHMAN ROBOT Safety System 3.3 21

Function

exceeds a set value, it will trigger a protective stop.

robot exceeds a set value, it will trigger a protective stop.

system.

Number

SF4

Joint Torque Monitoring

Cat. 2 stop

Cat. 0 stop

SF5

Joint Position Limit

Cat. 2 stop

Cat. 0 stop

SF6

Joint Speed Limit

Cat. 2 stop

Cat. 0 stop

SF7

TCP Speed Limit

Cat. 2 stop

Cat. 0 stop

SF8

TCP Force Limit

Cat. 2 stop

Cat. 0 stop

Safety

Name Description

SF4 Joint Torque Monitoring

The additional torque that joint received after compensating the

weight of tool in TCP setting, weight of workpiece in payload

setting in programming, and the weight of the robot body. Each

joint’s torque limit condition can be set. When the robot

SF5 Joint Position Limit

SF6 Joint Speed Limit

SF7 TCP Speed Limit

Each joint’s motion angle limit can be set. When the robot

Each joint’s motion speed range can be set. When the robot

The speed limit of the tool center point can be set. When the

The additional force that TCP received after compensating the

weight of tool in TCP setting and weight of workpiece in

payload setting in the programming. The force limit of the tool

center point can be set. When the robot exceeds a set value, it

SF8 TCP Force Limit

will trigger a protective stop. The force of the tool center point is

the external force at the tool center point estimated through the

model by the robot system. It is not the protection value of

applied external force at the tool center point by the robot

Table 6: SF4~SF8 Defined Safety Functions

Refer to the table below for the stop category and the action of fault detection for the safety functions.

When any fault other than discrepancy is detected in the safety functions, the system performs a Cat. 0

stop. When Cat. 0 stop occurs, reboot the robot system to recover from Cat. 0 stop status.

Safety

Function

Note: Stop categories in accordance with IEC 60204-1.

Name

Stop

Category

Reaction of

Fault Detection

Table 7: Stop Category and Reaction of Fault Detection of SF4~SF8

Refer to the relevant contents in the Software Manual for the setting of each item. Users can use any

method listed below to recover the robot from protective stop manually from SF4 to SF8:

 Pressing the STOP or PLAY button on robot stick

 Any operation on the icons in the left sidebar of the TMflow (except Shutdown)

 Pressing the FREE button in the end module of TM Robot

Safety Manual TECHMAN ROBOT Safety System 3.3 22

mitigation for human-robot collision.

include SF4 Joint Torque Monitoring in the human-robot collision safety protection measure.

biomechanical limits of each body region defined in ISO/TS 15066.

 Switching the mode on the robot stick

 Jogging the robot in UI Controller

 Changing digital/analog output value in UI Controller

 Entering Step Run in UI

 Pressing “Tes t” in UI to move the robot

 Pressing “Move (+)” in UI to move the robot (except Posture Setting, Vision Job, the interruption while

moving in Path node and Path Generator)

DANGER:

Pay attention that the "TCP Force” (Tool Center Point Force) is the external force at the tool

center point estimated through the model by the robot system, not the protection value of the

external force at the tool center point on the robot system. When the robot system exceeds

the external force value at the tool center point, the robot will perform a category 2 stop. In this

condition, applied forces will exceed this value. Therefore, clearly understand the amount of

the external force applied before the robot comes to a complete stop. The extent this value

will be exceeded will increase as the robot speed increases. This cannot be the primary risk

DANGER:

When the motion of TM Robot is passing the area near singular space, due to the nature of

singularity, the TCP force may be estimated incorrectly. Users can set the robot's motion

properly, e.g. do not set the motion too close to the singularity point in space, to avoid this

situation. This is a residual risk and users should apply risk assessment for the detection of

SF8 TCP force near the singularity case. SF8 TCP force should not be solely applied as the

only safety protection measure in human-robot collision case. It’s always recommended to

DANGER:

The speed, power and force limiting according to different body region in Human-Machine

Safety Settings are designed for user to quickly set up an initial robot application in

collaborative workspace following the biomechanical limits of each body region listed in

ISO/TS 15066. The initial parameters are tested* based on the conditions state in the same

UI, for details please refer to the software manual. User should still perform risk assessment

on real application before deployment, if any parameter needed to be modified, user can enter

More Limit Setting page to modify. User shall take responsibility for human body region which

is not listed in this graph, and ensure the robot does not have any chance to be in contact with

any vulnerable body region such as spine and hindbrain.

*The default speed limit on each body region is derived from the test based on the following

criteria:

• 100mm long and 0.67kg weight tool for X and Y axes impact test is installed on the robot

T C P. The weight of tool is compensated in TCP setting.

• 100mm long and 0.12kg weight tool for Z axes impact test is installed on the robot TCP.

The weight of tool is compensated in TCP setting.

• The impact force of the robot at the half reach collided with the sensor matches the

Safety Manual TECHMAN ROBOT Safety System 3.3 23

• The sensor used in the impact test is selected from which is described in document of

DGUV:FB HM 080 (August 2017).

Figure 1: X, Y, & Z axes

Note that the default speed limit when selecting Hand & Finger had been modified to a lower speed to

match the test with sensor described in document of DGUV:FB HM 080 (August 2017). If you upgrade your

Robot from previous version of Safety System to Safety System 3.3 by software update, the speed limit

value of Hand & Finger will still keep the original setting. Re-select the body region or click the default

button under Human-Machine Safety Setting page to update the speed limit value of Hand & Finger to align

with the speed limit value of Hand & Finger in Safety System 3.3.

2.3.5 SF10~SF14 Safety Output Functions

SF10~SF14 provides the safety output functions connecting to other devices for system integration. Refer

to the table below for the stop category, the definition of the triggered status, the action of the output signal,

and the action of the fault detection. When any fault other than discrepancy is detected in the safety

functions, the system performs a Cat. 0 stop. When Cat. 0 stop occurs, reboot the robot system to recover

from Cat. 0 stop status. For the related connections and usages, refer to the Hardware Installation Manual

of the respective hardware version. The definition of triggered status is when the connected device should

stop or enter the safety status. These safety outputs will be LOW when triggered.

For SF10 Robot ESTOP Output, note that it only reflects the emergence stop resulting from SF0 and SF1.

The emergency stop resulting from SF16 User Connected ESTOP Input without Robot Output will not

reflect on SF10.

For integration with safety output functions, it is necessary to add the corresponded safety input functions’

PFHd values for calculation. For example, when using SF10 Robot ESTOP Output to stop other machine

when emergency situation. It is necessary to put SF0 Robot Stick ESTOP into calculation, or to put both

external ESTOP button PFHd value and SF1 User Connected ESTOP Input into calculation. For those

outputs to stop other machine when internal safety functions triggered like SF13 Robot Internal Protective

Safety Manual TECHMAN ROBOT Safety System 3.3 24

Stop Output, it is needed to consider the corresponded input function, for example, SF7 TCP Speed Limit’s

value into calculation.

One exception of safety output functions integration in Safety System 3.3* is SF14 Robot Moving Output, it

does not need to add with the corresponding input function. SF14 is the combination of encoder monitoring

mechanism and output function, and all related PFHd has been taken into consideration.

*In Safety System 3.2, SF14 is marked with Cat. 3, as the output of encoder standstill function, and needed

to add with the structure and PFHd of SF2, which is a Cat.2 structure. In Safety System 3.3, they are all

considered in SF14.

Safety Manual TECHMAN ROBOT Safety System 3.3 25

Occurs

SF1

Output

Settings

,15,17

moving)

Safety

Function

Number

Name

Output

Signal

Regular

Status

Definition

Triggered

Status

Output

signal of

Triggered

Status

Action of

Output when

Discrepancy

Detected

from Safety

IO Input Ports

Action of

Output

when

System

Cat. 0

Stop

Action of

Output

when

System

Cat. 1

Stop

Action of

Fault

Detection

SF10

SF11

SF12

SF13

Robot

ESTOP

Output

User

Connected

External

Safeguard

User

Connected

External

Safeguard

Output for

Human–

Machine

Safety

Robot

Internal

Protective

Stop Output

HIGH

ESTOP

result from

SF0 and

Protective

Stop result

from SF3

External

Safeguard

Input result

from SF9

Protective

Stop result

from

SF4,5,6,7,8

LOW LOW LOW LOW

LOW LOW LOW HIGH

For SF 15

LOW

LOW HIGH

For Others

Cat. 0

stop

Cat. 0

stop

Cat. 0

stop

Cat. 0

stop

Any joint

speed

SF14

Robot

Moving

Output

HIGH

moves no

less than

0.3˚/s

LOW -- LOW LOW

Cat. 0

stop

(Robot is

Table 8: Output Signal and Action of Fault Detection of SF10~SF14

Safety Manual TECHMAN ROBOT Safety System 3.3 26

Number

triggered.

Safeguard Output

Stop other devices when safeguard connected to SF3 of the robot

triggered.

Settings

moves, e.g.

stand still while the other one is moving)

use the safety device to stop both the robot and other machine at the same time.

Safety

Function

Refer to the table below for indication of the example of application using the safety functions.

Name Example of Application

SF10 Robot ESTOP Output

SF11

User Connected External

SF12

SF13

Safeguard Output for

Human–Machine Safety

Robot Internal Protective

Stop Output

SF14 Robot Moving Output

WARNING:

SF14 Robot Moving Output is designed for stopping the other machine when the robot is

moving. When the robot is not moving, the output is HIGH, and this signal is provided to allow

other machine’s movement, not be used to stop the other machine. To stop the other machine

while the robot is standstill, use other measures such as the safeguard output of the robot or

Stop other devices when emergency stop button connected to the robot

Stop other devices or let it change to Human–Machine Safety Settings

when safeguard connected to SF9 of the robot triggered.

Stop other devices when robot is stopped for SF4,5,6,7,or 8.

Stop other devices when the robot is stopped for SF15 Enabling Device.

Stop other devices when the robot is stopped for SF17 Cartesian Limit

Prevent other devices from moving when the robot

application for robot mounted on an AGV or motional axis. (One should

Table 9: Application example of Safety Output Function

2.3.6 SF15 and SF16 Safety Input Functions

SF15 and SF16 provides more safety input functions for system integration.

SF15 User Connected Enabling Device Input provides the dual channel input ports for user to connect to a

three-position enabling device when risk assessment indicates. Enable this safety function in the Safety

Setting in the software to use it by referring to the Software Manual of the respective software version. Note

that the Open or Close status of this safety input will not affect the operation in Auto Mode. When this

function is enabled and connected to the enabling switch, in Manual Mode, all manual control operations

are enabled only when users press the three position enabling device in the middle position. If the Enabling

Device is released or fully pressed, the robot performs a protective stop. When starting a manual trial run of

the project pressing the PLAY button, the Enabling Device should be pressed in the middle position. When

Enabling Device is released or fully pressed during the Manual Trial Run mode, the Project Speed will

always automatically return to 5%. Connect this safety function only to the three-position enabling device

Safety Manual TECHMAN ROBOT Safety System 3.3 27

Number

Device Input

Others: Cat. 0 stop

without Robot ESTOP Output

Others: Cat. 0 stop

Mode.

compliant with IEC60204-1. Note that the input of this safety function has two input statuses only, so the

Enabling Device should not have an enabled output during the procedure from the fully pressed status to

the fully released status.

SF16 User Connected ESTOP Input without Robot ESTOP Output provides an emergency input function

without triggering SF10 Robot ESTOP Output. This safety function provides the possibility to prevent the

deadlock of the emergency stop between the robot and other devices/machines in different system

integration design.

Refer to the table below for the stop category and the reaction of fault detection of the safety functions. The

functions come with discrepancy detection to maintain the safety status when detecting conflicting signals

from a dual channel input. When discrepancy occurs, the system will enter lock in a safety status of Cat.1

stop. To resume from the safety status, first check the input wiring, correct it, and follow the steps below to

resume.

1. Let the dual inputs open and close again. At this time, the robot arm will be re-powered. The Indication

Light Ring will have the light blue light on to indicate the Safe Start up Mode.

2. Press the Stop Button on the Robot Stick for about three seconds. The robot will perform the

calibration action of the start-up process and return to the previous operating mode.

When any fault other than discrepancy is detected in the safety functions, the system performs a Cat. 0

stop. When Cat. 0 stop occurs, reboot the robot system to recover from Cat. 0 stop status.

Safety

Function

SF15

SF16

Note: Stop categories in accordance with IEC 60204-1.

Name Stop Category Reaction of Fault Detection

User Connected Enabling

User Connected ESTOP Input

Cat. 2 stop

Cat. 1 stop

Discrepancy: Cat.1 Stop

Safety Manual TECHMAN ROBOT Safety System 3.3 28

Table 10: Stop Category and Reaction of Fault Detection of SF15 and SF16

DANGER:

Enabling Devices only stop the robot in Manual Mode and will not stop the robot in Auto

Number

SF17

Cartesian Limit A

Cat. 2 stop

Others: Cat. 0 stop

Note: Stop categories in accordance with IEC 60204-1.

setting the restricted space and the safeguarded space in system integration.

2.3.7 SF17 Cartesian Limit A

SF17 provides a safety function for users to set Cartesian limit on the robot. Cubical and cylindrical limits

can be set, and both TCP and elbow are monitored. Refer to the table below for the stop category and the

reaction of fault detection and the Software Manual of the respective software version for the parameters

and procedure of setting.

To resume from this safety function, following the steps below:

1. Switch to the Manual Control Mode.

2. Press the FREE button on the end module of the robot to hand guide the robot to leave the limited

space.

Safety

Function

Name Stop Category Reaction of Fault Detection

2.3.8 SF18 Cartesian Limit B

SF18 provides a safety function for users to set Cartesian limit on the robot. Cubical and cylindrical limits

can be set, and both TCP and elbow are monitored. When robot exceed this Cartesian limit, the robot

decrease the robot speed to which is set in Human-Machine Safety Settings. Refer to the table below for

the stop category and the reaction of fault detection and the Software Manual of the respective software

version for the parameters and procedure of setting.

Table 11: Stop Category and Reaction of Fault Detection of SF17

WARNING:

SF17 Cartesian Limit A is designed for the robot to monitor once the robot's movement goes

beyond the set limit and the robot performs a protective stop. It does not mean the spot to

monitor will not exceed the limit due to the stopping time and the stopping distance. Take the

stopping time and the stopping distance into consideration when using this safety function for

To resume from this safety function, following the steps below:

1. Switch to the Manual Control Mode,

(1) Press the FREE button on the end module of the robot to hand guide the robot to leave the limited

space. Or,

(2) Use the controller in the software to jog the robot to leave the limited space.

2. Under any other Mode, let robot leave the limited space by programming.

Safety Manual TECHMAN ROBOT Safety System 3.3 29

Number

SF18

Cartesian Limit B

Others: Cat. 0 stop

Note: Stop categories in accordance with IEC 60204-1.

with a protective measure.

changed and saved.

Safety

Function

2.3.9 Safety Checksum

This function is intended for generating a "Checksum" from the safety settings and showing on the UI for

Name Stop Category Reaction of Fault Detection

Table 12: Stop Category and Reaction of Fault Detection of SF18

DANGER:

Cartesian Limit cannot be used as the only safety measure for preventing collisions between

human and the robot. When this safety function is used, other means should be provided to

prevent human or the limb enters the limited space or detect the entering of the limited space

users to quickly check the safety settings when user modified or type-in safety parameters to other robots.

The Safety Checksum indication displayed on the upper bar shows the applied safety settings and can be

read from left to right. For example: FE55. Different indication, including tests or numbers, indicates for

different safety setting configuration.

Figure 2: Checksum

WARNING:

The Safety Checksum changes only when the limits or settings in safety setting been

Safety Manual TECHMAN ROBOT Safety System 3.3 30

when recovering from the emergency stop.

system, release the FREE button immediately, which will lock the robot joint brakes.

3. Safety Related Operation

These are the operating instructions for Safety-related robot functions and designs.

Joint Movement without Drive Power

The conditions of robot without driving force are emergency stop, start up from the packing pose, and loss of power.

The first two can enter Safe Start up Mode when the emergency switch resets, and the latter is the situation when

the robot loses external power entirely. The following describes how to operate it:

During an Emergency Stop Procedure

The brake of each joint axis will automatically lock the joint, to avoid unlimited sagging of the robot's joints

due to gravity. If you need to move the robot to resolve the condition, follow the steps listed below:

1. Releasing the Emergency Switch energizes the power to the robot.

2. Wait 10 seconds to enter the Safe Start Up Mode. The Indication Light Ring will turn light blue.

3. Press the FREE button continuously to release the joint axis brake and move the robot.

4. After the situation is resolved, press the stop button on the Robot Stick for about three seconds, the

robot will perform the calibration startup process and return to the original operating mode.

CAUTION:

All personnel should be outside of the robot’s operational space (areas that robot can reach)

Extending the Robot from the Packing Pose

Refer to the Software Manual for the operation of extending the robot from the Packing Pose. The

emergency stop reset method is in Section 2.3.1.

DANGER:

When using the FREE button to release brakes without motor power, the robot may sag due

to gravity. Be prepared to support the robot system. If it not possible to support the robot

Power Loss

If power loss to an end-effector can result in a hazardous condition (e.g. dropping of a workpiece), possible

methods to reduce the risk may include but are not limited to:

• Use the 24V electrical output provided by the control box to supply the power to end effector instead

of using the End Module of robot to supply power.

• Install an independent power supply for the end effector.

• If the end effector is a pneumatic control, use a low potential actuation design.

Safety Manual TECHMAN ROBOT Safety System 3.3 31

the safeguarded space.

• Select the end effector with self-maintaining function / mechanical design.

If it is necessary to manually move the arm joint:

1. Remove the joint module protective cover screw and the joint module protective cover

2. Press the brake solenoid valve to release the brake

Refer to the brake release illustration in the Hardware Installation Manual.

Operation Mode and Mode Switching

TM Robot has two operation modes: Manual Mode (reduced speed and high speed) and Auto Mode. The modes

are visually distinguishable by the color of the mode indicator on the Robot Stick and the Indication Light Ring on

the robot’s end module. The robot is in Auto Mode when starting up.

Auto Mode

In Auto Mode the Indication Light Ring on the end module displays blue light and the Mode Indicator on the

Robot Stick is in Auto position. The user can press the Robot Stick Play/Pause button to play/pause the

robot program. The robot speed plays according to the project speed. In Auto Mode, the FREE button on

the end module does not actuate, and cannot perform Hand Guiding operation.

Auto Remote Mode is a mode that can only be accessed from Auto Mode when user gets control

permission and no project running. It is intended to let user implement remote control from remote side, e.g.

Fieldbus command, while these remote control commands are forbidden in the other modes. For switching

to Auto Remote Mode, click the Auto Remote Mode icon on the upper bar to permit remote control

commands under this mode.

Manual Mode

In Manual Mode the Indication Light Ring on the end module displays in green and the Mode Indicator on

Robot Stick is in Manual position. In Manual Mode, it can be divided into Manual Control Mode (Manual

Reduced Speed), Manual Trial Run Mode (Manual High Speed), and Hand Guide Mode. When the

protective stop occurs, the manual control operation in Manual Control Mode and Hand Guide Mode are

prohibited by the system.

3.2.2.1 Manual Control Mode (Manual Reduced Speed)

In Manual Control Mode, the user can jog the robot with controller UI in TMflow or the Robot Stick. If the

Safety Manual TECHMAN ROBOT Safety System 3.3 32

WARNING:

Wherever possible, the manual mode of operation shall be performed by all persons outside

functionality.

robot speed exceeds 250 mm/sec, it will enter an error stop state.

3.2.2.2 Hand Guide Mode

Hand Guide Mode can be activated in Manual Control Mode only. Press and hold the FREE button on

the End Module to enter Hand Guide Mode, and release the FREE button to return to Manual Control

Mode.

3.2.2.3 Manual Trial Run Mode (Manual High Speed)

In Manual Trial Run Mode, users can test the robot program by navigating to the TMflow project editing

page and pressing the Play/Pause button on the Robot Stick. The initial project speed will reduce to 5%

during each trial run, forcing the path motion of the robot lower than 250 mm/s. The +/- buttons on the

Robot Stick are for the adjustment of the project run speed. Each button press increases or decreases

project run speed by 5%.

WARNING:

The person should be outside of the safeguarded space when using Manual Trial Run Mode.

Switch Between Modes

For how to switch between modes, refer to the latest Software Manual of the respective software version of

the robot system.

DANGER:

Prior to selecting automatic operation, any suspended safeguards shall be set back to full

Hold to Run

When the TM Robot is in Manual Control Mode, the functions include:

• joint angle movement

• robot base end movement

• tool base end movement

Safety Manual TECHMAN ROBOT Safety System 3.3 33

• self-defined base end movement

• move to visual initial position

• visual servo action

• step run

• move to point

• hand guiding

• others

Hold to Run has two categories:

• Jog the robot by continuously pressing the + / - Button of the Robot Stick.

• Jog the robot by continuously pressing the + / - Button in TMflow software.

Once the + / - Button is released, the robot will stop operation immediately and will continue operation when

pressed again. If TMflow connects to the robot through Ethernet or Wi-Fi, the robot will automatically issue a

protective stop when releasing the + / - Button or the connection is broken. Depending on the quality of connection,

there may be a maximum detection delay of 800ms for loss of communication. Using the physical button to perform

Hold to Run function, the detection time of releasing the button is up to 30ms.

Singularity Point

The motion of an articulated robot is often limited by the kinematic design, and cannot perform Cartesian motion

control under all joint positions. The joint position that will cause the robot to be unable to perform Cartesian control

is a singularity point. When the robot encounters a singularity point, it will stop motion and initiate a warning.

Three types of singularity point for TM Robot:

• Internal Singularity Point in Space

• Extensible Singularity Point in Space.

• Wrist Singularity Point in Space.

Internal Singularity Point in Space:

The distance from the intersection of the rotational axes of the fifth joint and the sixth joint to the extended line of

the rotational axis of the first joint is defined as R

. The cylindrical space that is formed by R

offset

as the radius

offset

and centered on the extended line of the rotational axis of the first joint is the Internal Singularity Point in Space. As

soon as the robotic arm approaches the Internal Singularity Point in Space, the arm will stop and issue a warning.

The R

values of each product series are shown in the following table:

offset

Main model R

offset

TM5 Series 122.3 mm

TM12/14 Series 156.3 mm

Table 13: The R

values of each product series

offset

Safety Manual TECHMAN ROBOT Safety System 3.3 34

offset

Figure 3: The Definition of R

offset

Extensible Singularity Point in Space:

When the third joint is almost at its zero degree, which means the robot is almost at the maximum working radius.

The space exceeding this radius is the Extensible Singularity Point in Space. In this space, the robot will stop and

report a warning due to exceeding the motion range of the robot.

Safety Manual TECHMAN ROBOT Safety System 3.3 35

workspace area

Maximum

Extensible Singularity Point in Space

The maximum working range can be achieved when the third joint is almost at zero degrees

Figure 4: Extensible Singularity Point in Space

Wrist Singularity Point in Space:

When the rotational axes of the fourth and the sixth joints are parallel, the robot will enter the Wrist Singularity Point

in Space. At this time, the motion of the arm will cause a large-angle displacement of the fourth joint, but it will be

stopped due to stop criteria of motion speed. Once the robot enters the Wrist Singularity Point in Space, it will stop

and report an error.

Safety Manual TECHMAN ROBOT Safety System 3.3 36

When the fourth and sixth joint are nearly parallel, the robot is about to enter the Wrist

Singularity Point in Space.

Figure 5: Wrist Singularity Point in Space

The Solution when Encountering Singularity Point in Space:

When the robot reports singularity, confirm the posture of the robot. If the tool end path crosses the internal cylinder

as shown in the figure below, check the first point description. If the rotational axes of the fourth and sixth joints of

the robot are parallel, check the second point description below.

1. When the arm reports a warning due to the Internal Singularity Point in Space, press the FREE button to release

it from the posture. Change the point position or change the motion type to PTP between the points to avoid the

arm path between the points crossing the Internal Singularity Point in Space, as shown in the figure below.

Figure 6: The Solution when Encountering Singularity Point in Space (1/2)

When the path crosses the Internal Singularity Point in Space, singularity will be triggered. Adjust the path and

confirm that it will not cross the Internal Singularity Point in Space.

2. When the robot reports a warning because of entering the Wrist Singularity Point in Space, press the FREE

button to release it. When the rotational axes of the fourth and the sixth joint are in parallel, if users still try to

perform Cartesian motion, the Wrist Singularity Point in Space will be encountered. At this time, the method in

the following figure can be used to avoid the rotational axes of the fourth and the sixth joints being parallel.

Safety Manual TECHMAN ROBOT Safety System 3.3 37

Figure 7: The Solution when Encountering Singularity Point in Space (2/2)

This example demonstrates how to avoid the rotational axes of the fourth and sixth joint being parallel, when

the user needs to move the robot according to tool Z-axis.

Safety Manual TECHMAN ROBOT Safety System 3.3 38

Device

Trial Run

Replacing the Robot Stick in Local Control

When users use other means to replace the local control function of the Robot Stick, the Robot Stick should not be

accessed and used in local control at the same time. For example,

 Do not use devices like teach pendants when using the Robot Stick at the same time in local control.

 Do not enable and use the teach pendant function* on a keyboard when using the Robot Stick at the same

time in local control.

* Supported by the software version newer than SW1.72 with the Keyboard Hot Key functions.

For initiation of robot motion under local control, the table below summarized executing project using PLAY function,

hold to run or speed adjustment using +/- functions according to different control method in respective mode. The

“X” means the user is allowed to use the function.

Operation

Mode

Manual

Control

Mode

Manual

Mode

Auto Mode

The user can Play Using The user can +/- Using

Configure

Program

on Local

Machine

(Fieldbus)

Execute project Speed & Hold to Run Speed Only

Fieldbus

command

from

Client

Hot Key

Robot

Stick

Configure

Program

on Local

Machine

(Fieldbus)

Fieldbus

command

from

Client

The user Get

Control

Permission

on either

Robot UI

(Local Machine),

or Client UI

(Client Device)

Robot

Stick

Y X X X X X X X

N X X X X

Y X X X X X X X X X

N X X X X X

Y X X X X X X* X* X* X* X*

N X X X X* X* X* X*

Hot Key

Speed &

Hold to Run

Auto

Remote

Mode

* Needs to enable speed adjustment under Auto Mode

Safety Manual TECHMAN ROBOT Safety System 3.3 39

Y X X X X X X* X* X* X* X*

N X X X X X* X* X* X*

Table 14: Control Methods in Respective Modes Summary

4. Compliance of Safety Regulations

This section describes the compliance and certification of this product to international safety regulations.

This product complies with to the following international safety regulations:

ISO 10218-1:2011

ISO/TS 15066

ISO 13849-1:2015

Certification: Third-party certification (refer to the certificate in Appendix A)

Compliance

This product complies with the combined scope of ISO 10218-1:2011 and ISO/TS-15066.

The relevant design and corresponding provisions in safety regulations of this part are listed in the following sections.

Requirement of Enabling Device

The power and force limiting functions provide the alternative measures for the requirement of an enabling

device per ISO/TS 15066:2016.

Means are provided for connection of an Enabling device when required by the risk assessment.

Access of Safety Setting

TM Robot's safety setting has been integrated with the user's permission system of the entire product.

Safety Manual TECHMAN ROBOT Safety System 3.3 40

5. Declaration of Incorporation

The following is based on the Declaration of Incorporation in application of 2006/42/EG, Annex II, No. 1 B

The robot product of the Corporation is a partly completed machinery. When it is put into automation applications, it

needs to be integrated with other equipment, and appropriately installed with the safety related measures and design

before it can be used. When the semi-finished products are to put on the market, the following requirements according

to 2006/42/EC Annex I need to be achieved. It must be noted that since the TM Robot product is easy to use, the

“system integrator” here refers to the end user who uses the product directly through simple installation.

A: Not related

B: Satisfied by machinery equipment provider

C: Responsibility of the system integrator

Attention: in the following tables:

 Items marked as A: The scope of use of this product has been exceeded, and is not included into the

consideration, or it is not directly related to this product.

 Items marked as B solely: The items that are to be satisfied by the machinery equipment provider, meaning the

machinery provider has satisfied or has specified in each of the Software and Hardware / Safety Manual. In the

latter case, the system integrator is still responsible for the full compliance with specification of machinery

equipment provider. In addition, in the entire system, the satisfaction of machinery equipment belonging to the

system but not belonging to this product is not included here, and the system integrator must be responsible for it.

 Items marked as C solely: The item cannot be satisfied by this product. The system integrator must implement

additional measures.

 Items marked as both B and C:

1. When the item can be satisfied in using this product itself, the machinery equipment provider of this product

shall satisfy it.

2. When the system integrator replaces the related functions of this product through system integration, the

system integrator shall satisfy it. For example:

 Replacing the emergency switch of the Robot Stick with an external emergency switch connected to the

Emergency Switch Port

 Replacing the Play/Stop Button of the Robot Stick with user-defined IO or the functions of equivalent

Safety Manual TECHMAN ROBOT Safety System 3.3 41

Number

Original Language Items

1.1

Essential Requirements

1.1.1

Definitions

X X

1.1.2

Principles of safety integration

X X

1.1.3

Materials and products

1.1.4

Lighting

1.1.5

Design of machinery to facilitate its handling

1.1.6

Ergonomics

X X

1.1.7

Operating positions

1.1.8

Seating

1.2

Control Systems

1.2.1

Safety and reliability of control systems

X X

1.2.2

Control devices

X X

1.2.3

Starting

X X

1.2.4

Stopping

X X

1.2.4.1

Normal stop

X X

1.2.4.2

Operational stop

X X

1.2.4.3

Emergency stop

X X

1.2.4.4

Assembly of machinery

1.2.5

Selection of control or operating modes

X X

1.2.6

Failure of the power supply

1.3

Protection against mechanical hazards

1.3.1

Risk of loss of stability

1.3.2

Risk of break-up during operation

X X

1.3.3

Risks due to falling or ejected objects

X X

1.3.4

Risks due to surfaces, edges or angles

X X

1.3.5

Risks related to combined machinery

1.3.6

Risks related to variations in operating conditions

1.3.7

Risks related to moving parts

X X

1.3.8

Choice of protection against risks arising from moving parts

1.3.8.1

Moving transmission parts

X X

1.3.8.2

Moving parts involved in the process

X X

1.3.9

Risks of uncontrolled movements

1.4

Required characteristics of guards and protective devices

1.4.1

General requirements

functions.

When this type of design replaces the original function of this product, the system integrator shall be

responsible for the equivalence of the replacement.

3. The machinery equipment provider satisfies this item in normal conditions, but in extraordinary conditions, the

satisfying of this item is the responsibility of the system integrator. For example:

 The product will not break in normal operation, without a collision. However, the product can break in

the event of a strong collision due to incorrect programming setup and safety setting during operation.

* A – Scope Exceeded, B – Manufacturer Provided, C – May Require Additional Risk Reduction Measures

Safety Manual TECHMAN ROBOT Safety System 3.3 42

1.4.2

Special requirements for guards

1.4.2.1

Fixed guards

1.4.2.2

Interlocking movable guards

1.4.2.3

Adjustable guards restricting access

1.4.3

Special requirements for protective devices

1.5

Risks due to other hazards

1.5.1

Electricity supply

1.5.2

Static electricity

1.5.3

Energy supply other than electricity

1.5.4

Errors of fitting

1.5.5

Extreme temperatures

1.5.6

Fire

1.5.7

Explosion

1.5.8

Noise

X X

1.5.9

Vibrations

1.5.10

Radiation

1.5.11

External radiation

1.5.12

Laser radiation

1.5.13

Emissions of hazardous materials and substances

X X

1.5.14

Risk of being trapped in a machine

1.5.15

Risk of slipping, tripping or falling

1.5.16

Lightning

1.6

Maintenance

1.6.1

Machinery maintenance

1.6.2

Access to operating positions and servicing points

1.6.3

Isolation of energy sources

1.6.4

Operator intervention

1.6.5

Cleaning of internal parts

1.7

Information

1.7.1

Information and warnings on the machinery

1.7.1.1

Information and information devices

X X

1.7.1.2

Warning devices

X X

1.7.2

Warning of residual risks

1.7.3

Marking of machinery

1.7.4

Instructions

1.7.4.1

General principles for the drafting of instructions

1.7.4.2

Contents of the instructions

1.7.4.3

Sales collateral

Table 15: Declaration of Incorporation

Safety Manual TECHMAN ROBOT Safety System 3.3 43

Appendix A. Certificate of Compliance and Declaration of Incorporation

The "manufacturer" in the article above should be deemed to be "original equipment manufacturer."

Safety Manual TECHMAN ROBOT Safety System 3.3 44

The "manufacturer" in the article above should be deemed to be "original equipment manufacturer."

Safety Manual TECHMAN ROBOT Safety System 3.3 45

The "manufacturer" in the article above should be deemed to be "original equipment manufacturer."

Safety Manual TECHMAN ROBOT Safety System 3.3 46

Safety Manual TECHMAN ROBOT Safety System 3.3 47

Appendix B. Verifications of EMC Compliance

Safety Manual TECHMAN ROBOT Safety System 3.3 48

Safety Manual TECHMAN ROBOT Safety System 3.3 49

WARNING:

speeds or with heavier payloads.

(ms)

(deg)

(ms)

(deg)

(ms)

(deg)

Appendix C. TM Robot Stopping Time and Distance for all Series Product Models

The stopping time and stopping distance of the Cat.1 stop functions of this product at different speeds and with different

payloads are shown below.

Any moving robot requires some distance to stop. When stopping a robot, make sure that

TM5-700 Series

there is no interference with other equipment. This requires more distance at high operating

Stop Time and Stop Distance Tab l e

Percentage of

Maximum

Payload（％）

100

Extension(％) Speed(％)

100

First joint Second joint Third joint

Stop

Time

364 9.00 600 9.29 442 8.97

377 17.96 516 18.15 466 17.91

381 26.55 657 27.13 486 26.92

455 8.99 567 9.17 422 8.96

531 17.95 594 18.08 457 17.94

610 26.34 528 27.72 457 23.41

367 8.98 534 9.30 432 9.00

396 17.94 501 18.19 530 18.02

427 26.76 526 27.80 541 28.81

378 9.01 531 9.23 475 8.99

401 17.95 547 18.12 478 17.97

575 26.75 551 26.99 570 26.91

496 8.96 529 9.29 433 8.97

545 17.96 506 18.14 526 17.98

563 26.46 526 28.36 583 27.73

517 8.94 568 9.38 636 9.08

598 17.90 524 18.10 545 18.16

614 26.58 575 28.53 527 28.75

565 8.96 585 9.26 567 9.12

570 17.92 585 18.16 675 18.28

579 26.33 356 30.98 666 27.40

566 8.95 588 9.34 625 9.28

576 17.92 578 18.26 656 18.26

570 26.88 343 31.10 550 27.56

597 8.94 576 9.34 681 9.34

593 17.86 516 18.14 555 18.09

596 26.00 544 26.45 528 28.80

Stop

Distance

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

Safety Manual TECHMAN ROBOT Safety System 3.3 50

Table 16: Stopping Time and Distance for TM5-700 Series

(ms)

(deg)

(ms)

(deg)

(ms)

(deg)

TM5-900 Series

Stop Time and Stop Distance Table

Percentage of

Maximum

Payload（％）

Extension(％) Speed(％)

33 519 8.96 626 9.24 457 8.99

66 512 17.95 555 18.03 475 17.93

100 466 25.68 563 27.20 476 27.09

33 374 8.97 598 9.32 444 8.96

66 719 17.95 510 18.11 636 18.12

100 664 26.33 521 27.34 650 27.41

100

33 508 8.98 660 9.19 629 9.23

66 589 17.97 666 18.20 536 18.09

100 476 26.86 575 27.62 635 27.06

33 635 8.93 633 9.27 518 9.00

First joint Second joint Third joint

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

366 8.98 524 9.25 428 8.97

412 17.93 518 18.23 510 18.04

442 26.57 508 24.20 498 28.66

100

Table 17: Stopping Time and Distance for TM5-900 Series

66 645 18.00 640 18.16 647 18.19

100 668 26.73 569 28.14 676 27.73

100

366 9.02 506 9.22 565 8.96

479 17.96 522 18.16 514 16.93

503 26.58 517 23.61 485 28.62

33 474 8.99 572 9.15 662 9.21

66 571 18.02 573 18.22 640 18.18

100 568 26.94 563 28.00 637 27.36

33 508 9.00 691 9.31 627 9.18

66 566 18.10 641 18.23 652 18.26

100 583 26.72 534 28.45 680 27.56

100

549 9.04 542 9.28 436 8.97

645 18.16 551 18.11 520 18.13

594 26.60 569 23.15 499 28.78

Safety Manual TECHMAN ROBOT Safety System 3.3 51

（％）

(ms)

(deg)

(ms)

(deg)

(ms)

(deg)

TM14 Series

Stop Time and Stop Distance Table

Percentage

of Maximum

Payload

Extension(％) Speed(％)

100

First joint Second joint Third joint

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

33 416 6.01 554 6.18 511 8.83

66 662 12.00 650 12.33 621 17.84

100 482 18.24 635 18.58 510 26.32

33 374 5.99 637 6.41 527 8.94

66 643 11.99 641 12.34 689 17.66

100 644 18.18 654 18.65 545 26.54

100

482 6.04 530 6.27 453 8.42

531 11.90 657 12.37 589 18.28

624 18.17 626 17.64 575 28.86

33 680 6.00 623 6.36 598 9.17

66 684 11.98 605 12.20 632 18.91

100 690 18.13 595 18.54 631 27.19

33 595 5.99 576 6.35 635 9.28

100

66 597 11.96 557 12.42 600 18.33

100 581 18.13 557 18.51 599 27.50

100

548 5.98 530 6.38 432 8.52

568 11.84 576 12.41 567 18.32

568 18.25 589 17.75 531 28.77

33 591 5.99 574 6.34 529 9.10

66 608 11.97 575 12.38 557 18.22

100 582 18.15 585 18.89 556 27.27

33 611 5.99 594 6.48 575 9.12

66 615 11.99 616 12.26 671 18.30

100 618 18.23 604 18.98 571 27.34

100

570 6.06 568 6.29 575 8.95

567 12.06 552 12.34 587 18.20

568 18.39 591 17.61 544 28.87

Table 18: Stopping Time and Distance for TM14 Series

Safety Manual TECHMAN ROBOT Safety System 3.3 52

(ms)

(deg)

(ms)

(deg)

(ms)

(deg)

TM12 Series

Stop Time and Stop Distance Table

Percentage of

Maximum

Payload（％）

Extension(％) Speed(％)

33 365 6.02 634 6.27 674 9.35

66 364 12.00 557 12.18 588 18.12

100 473 18.20 559 18.48 615 27.26

33 368 6.01 563 6.27 584 9.19

66 634 12.01 531 12.24 653 18.30

100 621 18.17 541 18.45 552 27.73

33 541 5.98 597 5.22 544 8.94

100

66 564 12.01 587 12.21 532 18.14

100 591 18.17 592 17.80 569 28.90

33 662 6.02 644 6.16 632 9.20

66 657 12.01 645 12.26 657 18.10

100 659 18.16 666 18.67 695 27.08

33 501 6.03 664 6.12 680 9.36

First joint Second joint Third joint

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

Stop

Time

Stop

Distance

100

66 661 12.00 601 12.33 676 18.30

100 661 18.16 588 18.91 570 27.50

33 539 6.02 545 6.38 513 9.10

66 543 12.01 545 12.36 520 18.15

100 530 18.40 565 17.88 591 28.82

33 584 5.99 540 6.19 606 9.17

66 596 11.99 560 12.52 592 18.01

100 603 18.14 535 18.88 572 27.07

33 579 6.06 549 6.26 613 9.33

66 581 12.09 564 12.52 606 18.12

100 585 18.27 556 19.24 582 27.75

33 580 6.06 558 5.36 608 9.34

66 548 12.12 537 12.39 547 18.15

100 564 18.41 518 18.14 611 27.50

Table 19: Stopping Time and Distance for TM12 Series

Safety Manual TECHMAN ROBOT Safety System 3.3 53

Safety Manual TECHMAN ROBOT Safety System 3.3 54

I648-E-04

0820

19888-320 D

Techman Robot Safety System 3.3 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Terms and Conditions Agreement

Contents

Revision History Table

1. Comprehensive Information

Overview

Applicable Product Version

Safety Warning Symbols

Safety Precautions

Validation and Responsibility

Limitation of Liability

Overall Safety Warning

Intended Use

Risk Assessment

2. Safety Function

2.1 Overview

2.2 General Information

2.2.1 Safety Function Definitions

2.2.2 Stopping Time and Stopping Distance in the Safety System

2.2.3 Software Safety Setting Permissions

2.3 Explanation of Safety Functions

2.3.1 SF0 Robot Stick ESTOP and SF1 User Connected ESTOP Input

2.3.2 SF2 Encoder Standstill

2.3.4 SF4~SF8 Defined Safety Functions

2.3.5 SF10~SF14 Safety Output Functions

2.3.6 SF15 and SF16 Safety Input Functions

2.3.7 SF17 Cartesian Limit A

2.3.8 SF18 Cartesian Limit B

2.3.9 Safety Checksum

3. Safety Related Operation

Joint Movement without Drive Power

During an Emergency Stop Procedure

Extending the Robot from the Packing Pose

Power Loss

Operation Mode and Mode Switching

Auto Mode

Manual Mode

3.2.2.1 Manual Control Mode (Manual Reduced Speed)

3.2.2.2 Hand Guide Mode

3.2.2.3 Manual Trial Run Mode (Manual High Speed)

Switch Between Modes

Hold to Run

Singularity Point

Replacing the Robot Stick in Local Control

4. Compliance of Safety Regulations

Compliance

Requirement of Enabling Device

Access of Safety Setting

5. Declaration of Incorporation

Appendix A. Certificate of Compliance and Declaration of Incorporation

Appendix B. Verifications of EMC Compliance

Appendix C. TM Robot Stopping Time and Distance for all Series Product Models