Service Home How To Procedures Haas Cobot 5 (HC5) - CL - Installation - AD0761

Haas Cobot 5 (HC5) - CL - Installation - AD0761

4.2 CL Installation

Last updated: 03/28/2024

Haas Cobot 5 (HC5) - CL - Installation

AD0761

Revision A - 05/2025

Introduction

This procedure will show you how to install the Haas Cobot 5 (HC5).

 Note: The Haas designed work cell made up of a CNC machine and a robot have been evaluated for compliance to CE requirements. Changes or variations to the Haas cell design should be evaluated for compliance to the applicable standards and are the responsibility of the user/integrator.

Machine Requirements:

Tool Requirements:

  • Mini Flat Head Screwdriver

 Note: Refer to the sales order for what components are included in the order. Orders will differ depending on the options that were purchased.

IMPORTANT:  For more information directly on the Hans Cobot, refer to the Hans Robot Operation Manual for Elfin Software.

 

The Haas Cobot 5 Package needs the following components to be Field Installed on a Haas Machine:

PART NUMBER DESCRIPTION

One of these Cobot Integration Kit and Safety Parameter:

93-1001057   Cobot Integration Kit Front Load CL-1 Front

93-1000997   Front Automation Safety Par Only

 Cobot Integration Kit and Safety Parameter

One of these Robot Safety Devices:

08-1899 Multi-Sided Light Curtain HRP Kit

08-1948 5-sided Light Curtain HRP Kit

08-1897 Laser Area Scanner Kit

 Robot Safety Device

Machine Setup

1

Install the door fully open sensor [1] . Install the sensor onto the auto door air cylinder [2]. This sensor cable can be routed along the inside of the enclosure to the conduit near the rear of the machine. Then the cable can be routed to the control cabinet as shown in the image [3].

See the next step about where to connect the door fully open cable to the control cabinet.

Note: Refer to the CL - Autodoor Installation for more information on how the autodoor is installed.

2

Connect the other end of the cable to the SIO PCB P27 RRI Door Open input. 

NOTE: Make sure the machine is turned OFF. 

Cobot Installation

1

Verify that the Cobot and its control box are from the same matching set with matching serial numbers.

There is a white decal with the Haas serial number [1]. Make sure these are the same on both boxes.

There is a yellow circle decal with an identification number [2]. Make sure these are the same on both boxes.

2

Install the base mount bracket onto the machine's enclosure using the provided button head cap screws.

Insert 2 button head cap screws into the tapped holes [1] on the machines enclosure. 

 Note: Lift open the machine door and secure the button head cap screws with the provided lock nuts, as shown in [3].

Install the bottom two button head cap screws, that will fasten into two PEM nuts [2].

3

Install the angled mounting bracket [1] with the 4 button head cap screws from the integration kit.

Note: Make sure the angle mounting bracket is oriented as shown in the image. 

Install the support leg using 3 button head cap screws [2]. 

Once fastened, lower the adjustable foot until it reaches the floor. This support will keep the Cobot stable during movements.

4

Fasten the parts table bracket [1] to the mount bracket installed in the previous step using the 4 FBHCS [2]. Use a bubble level to verify that the parts table is sitting roughly leveled.

Fasten the parts template [3] to the parts table bracket with the 4 BHCS [4].

5

The following step is intended for cutting longer pieces of stock.

Place the six provided spacers [1] and stack the two templates [2] from the kit on top of them.

Note: Ensure the templates are oriented as shown in the image.

Secure the parts template [3] to the parts table bracket using the 4 BHCS.

6

Remove the Cobot from the shipping box. 

Install the Cobot on top of the angled mounting bracket withthe 6 SHCS [1].

IMPORTANT: The Cobot is about 35 lbs and should be lifted with a device that can safely lift that weight. 

7

Place the Cobot control box [1] directly under the mounting bracket [2] and parts table [3]. This will ensure there is enough slack in the cables for the electrical installation.

8

Inside the Cobot packaging, there is a small bag [1] filled with spare parts including: 

  • Fuse
  • Screws (x2)
  • Control Box Keys

There is a medium bag [2] filled with an extra M12 connector. This cable can be used to configure inputs and outputs for the End I/O Module. 

There is a large size bag [3] filled with papers and a USB stick downloaded with the Cobot software.

Make sure to keep these spare parts somewhere safe for future use. 

Robot Electrical & Air - Installation

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

1

Connect Interface Box to Haas Machine:

The robot safety devices interface box 32-9018 has magnetic mounts to attach to the machine sheet metal. Mount the interface box [1] near the control cabinet so that the cables can reach.

Route the cable through the bottom of the electrical cabinet.

NOTE: For information on upgrading the interface box to the Robot Safety Devices Interface Box, refer to the Robot Safety Devices Interface Box - Installation - AD0703. 

2

Connect Interface Box to Haas Control Cabinet:

Connect cable 33-8562C E-STOP terminal block to TB-1B [1] and connect the Setup mode terminal block to TB-3B [1] on the SIO PCB.  

Plug the user relay into K9 and K10 [2].

Verify the jumper is installed on the SIO PCB at JP1.

Connect the pigtail cable labeled P1 SIO to the SIO PCB at P1 [3]

NOTE: If the machine has a Regen Vector Drive, unplug cable 33-0634 FILTER OV TO IOPCB P1 from P1 SIO and plug it into the connector FILTER OV FAULT on cable 33-8562C. If the machine does not have a Regen Vector Drive, do not plug anything into the connector FILTER OV FAULT.

Connect the RJ-45 cable [4] to Ethernet to USB adapter [5] (33-0636).  Connect the USB connector end to the Maincon PCB J8 top port. Add a ferrite filter [6] to the USB adapter.

Mount the 24VDC Power Supply [7] to the left side of the control cabinet and plug into connector labeled 24V PS on cable 33-8562C. Connect cable 33-1281 [8] to the 24VDC Power Supply [7] and plug into P3 on the PSUP PCB. 

3

Inside the Cobot control box, install part of the robot signals cable 33-1272. To do so, remove the safety connector [1] from the Cobot control box in order to install the different colored wires into their respective location

33-1272 cables [2] going to safety connector:

  • Gray wire to top 24V
  • Red wire to bottom 24V
  • Green wire to EI0
  • Brown wire to EI1
  • Jumper [3] from SA0 to SA1
  • Jumper  [4] from SB0 to SB1

 NOTE: The rest of the cables are not used. Make sure to ziptie up the leftover unused wires. 

4

Important: After installing all the cables from the robot signal cable 33-1272. Make sure that the fuse [1] remains installed at all times to protect the Cobot control box.

5

Connect Cobot to the Interface Box:

Connect the RJ45 ethernet cable [1] from the Cobot Control Box to the interface box. Add a ferrite filter [2] to the RJ-45 cable.

Connect the robot signals cable [3] from the Cobot Control Box to the interface box. 

Connect the 120 VAC Cobot Power Cable [4] to the external power source. 

Connect the robot power cable [5] from the control box to the Cobot.

Connect the teach pendant cable [6] from the control box to the teach pendant. 

NOTE: For more information regarding interlock fence, area scanner or light curtain installation, refer to the Robot Safety Device section below.

6

Make sure the Remote Jog Handle is installed onto the machine.

NOTE: For more information on the RJH-XL installation, refer to Remote Job Handle - Touch Large (RJH-XL) - Installation - AD0533. 

7

Steps 7 thru 9 are wiring and hose routing instructions for the pneumatic grippers. Refer to the grippers installation section lower on this page for the mechanical installation.

Install the dual air solenoid assembly [1] on to the side of the mounting bracket [2] while giving the airlines enough slack. Make sure it's in a position where it will not be in the way of the Cobot or operators working around the machine. Route the airline [3] under the machine back towards the CALM cabinet [4] as shown.

8

Inside the CALM cabinet, remove a plug from one of the CALM manifold ports and install the check valve [1] (58-1863) onto the port's fitting. Route the input airline [2] from the dual air solenoid assembly (from previous step) into the CALM cabinet and connect the airline to the check valve.

Turn the machine air supply ON.

9

Make sure to power OFF the control box [1].

Connect the solenoid cable from the dual air solenoid assembly [2] into the Digital Output on the Cobot control box [3]. Remove the connector from Cobot control box.

10

Install the different colored wires into their respective location:

  • Black/white cable into 0V
  • Black cable into DO0
  • Orange/white cable into 0V
  • Orange cable into DO1
  • Red/white cable into 0V
  • Red cable into DO2
  • Brown/white cable into 0V
  • Brown cable into DO3

Power ON the control box.

Robot Safety Device

IMPORTANT: DO NOT OPERATE THE ROBOT UNTIL YOU HAVE PROPERLY CONFIGURED AND TESTED THE OPERATION OF THE SAFETY DEVICE.

Light Curtain:

Cobot packages come with the light curtain emitter and receiver as the default safety device. Follow the procedure below for light curtain installation: 

Light Curtain Installation

NOTE: If the area scanner or HC10 Machine Ready kit was ordered, there will also be a 1M light curtain receiver and emitter. These come with all Cobots. 

Area Scanner:

If the machine came equipped with the area scanner option, the area scanner needs to be installed and configured to the space. Follow the procedure below for installation: 

Area Scanner Installation

First Power-UP

1

Power ON the Haas machine. 

Power ON the Cobot by flipping the power switch [1].

Power ON the Cobot teach pendant by pressing the circle [2]. 

Make sure that E-STOP [3] on the Cobot teach pendant is released. 

In order to change the language, click on the language drop down menu. Choose EN for English. To confirm this setting change, the Cobot teach pendant will have a popup asking to insert the username & password. 

Enter "admin" for both the username and password. 

2

Note: The Cobot teach pendant will have a popup asking to insert the username & password. To sign into the teach pendant use these credentials:

  • Username = admin
  • Password = admin

Go into Run mode. Press Enable. 

Go into Jog mode [1].

Move each joint to it's zero location with the Move Zero buttons [2]. 

3

Once the robot is in it's zero location, verify that the hash lines [1] align on either side of each joint on the Cobot. 

 IMPORTANT: If any joint hash lines [1] do not align, jog the specific joint accordingly until all the hash lines [1] do align. This position will be set in the next step as the new Cobot zero position.  

Connect an ethernet cable [2] from the Cobot control box into a computer.

On the computer, change the adapter setting to enable the ethernet port. 

Note: See next steps for help on changing adapter settings.

4

To change the adapter settings, open the settings page [1] on the computer, then click on Network & Internet [2] which will bring up the network status page.

Click on Change adapter options [3] then right click on Ethernet [4] and open up the properties window [5]. From there select the Internet Protocol Version 4 (TCP/IPv4) [6] option and click Ok. 

 

5

The ethernet settings will now be correct. Open a web browser window and type in the IP address of the Cobot[1]. 

Note: This is the same process as connecting a laptop to an HRP-1/2/3. For more information on connecting to the Cobot via ethernet, refer to the video on the HRP-Troubleshooting page that is in the Connect & Jog Haas Robot section. 

6

Download HRTool through HBC. On the Service section of HBC, navigate to Utilities > Documents and Software > 01 Control Software > 01 Next Generation Control > 10 Cobot Software > HRTool.zip.

Unzip the folder and navigate to HRToolsMaind.exe.

Insert the Cobot IP address found under the Systems tab.  Click Set. 

Go to the Config tab on HRTool.

Click "get" to see the actual vs. theoretical encoder values. 

Click "set" to set the theoretical to the actual encoder values. This step sets the Cobot's current position as it's new home position. 

7

Make sure that each joint's actual and theoretical encoder values match. 

NOTE: If the valuyes do not match, press "Set" again. 

8

On the teach pendant, navigate to System [1] and then Update System. 

Confirm the Cobot firmware [2] is either:

  • HR5.51H.16.beta.20231213.zip
  • HR6.4.9.tmp.20240919.zip

NOTE: Firmware version HR6.4.9.tmp.20240919.zip is compatible with all size cobots.

Refer to the Haas Cobot - Maintenance chapter for the firmware update procedure. 

9

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

  • 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
  • 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
  • 2194 [:] Enable Front Door Fully Open Switch to TRUE

Note: Machines with Software Version 100.20.000.1010 or higher will need to change the following parameter:

  • 2192 [:] Light Curtain Trigger Threshold to 0

Press [SETTING].

Set the Settings:

  • 372 Parts Loader Type to 3: Robot.
  • 376 Light Curtain Enabled to On

 

10

On the Haas pendant, press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

  • Maximum Jogging Speed to 7.9 inch/sec

Go to the Setup tab. Change the following:

WARNING: Setting this value incorrectly can cause the Robot Arm to not move correctly. 
 
  • Number of Grippers to the number of grippers.
  • Raw Gripper Clamp Output to 1.
  • Raw Gripper Unclamp Output to 2.
  • Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
  • Raw Gripper Clamp Type to OD/ID.
  • Finish Gripper Clamp Output to 3.
  • Finish Gripper Unclamp Output to 4.
  • Finish Gripper Clamp Delay to the clamp/unclamp duration in sec.
  • Raw Gripper Clamp Type to OD/ID.

Security Risk Level

1

IMPORTANT: Make sure to perform an appropriate risk-assessment and met all appropriate safety requirements. 

2

Based off the risk assessment, set the appropriate security risk level on the Cobot teach pendant. Navigate to Config > General Restrictions and tap of the desired security risk level [1] from 0 - 5.

Use the  "admin" code in the safety verification to change the security level.

NOTE: When the security risk level is lower, the robot will have a lower maximum speed, force, etc. When the security risk level is higher, the robot will have a higher maximum speed, force, etc. 

This security risk level will calculate the maximum allowable force, speed, power, momentum, elbow speed and elbow force [2] that the Cobot will withstand before Alarm 9150.10017 Collison Stop Error is triggered. 

IMPORTANT: The robot's programmed speed cannot be greater than the allowable speed from the security risk level. 

NOTE: For more information regarding alarms, refer to the Haas Cobot - Troubleshooting Guide. 

Activation

1

Download and load the configuration files by logging into the HAAS SERVICE PORTAL.

Download the safety automation option front/side configuration files.

Load the option configuration patch file to the control. Refer to the NEXT GENERATION CONTROL - CONFIGURATION FILE - DOWNLOAD/LOAD procedure.

2

Go to Parameters > Features > Robot to verify that the robot feature has appeared on the bottom.

3

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab [1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, the robot feature will need to be unlocked. This popup shows the machine's current software version, robot mac address and a generated code. Enter this information into HBC in order to receive the unlock code.

4

On HBC, go to the Service tab [1].

On the left hand side of the screen, click on Activations [2], and then select Cobot Installation [3] to begin the process to the get the Cobot unlock code.

The first step is to enter the Machine Serial Number [4] and the Cobot Serial Number [5] in the fields on HBC.

Once you have entered the correct information, press Next [6] in the bottom right corner and continue through the steps until you receive the unlock code.

Note: Make sure you are on the Cobot Installation tab [3] and not the Robot Installation tab. The Robot Installation is only used for the Haas Robot Packages. Using the Robot Installation for the Haas Cobots will result in an invalid unlock code.

5

Enter the Cobot's Haas Serial Number[1] and the unlock code to connect the robot to the machine. 

 Note: This step can only be completed by a HFO Service Technician.

 Note: The machine needs to be activated before the Cobot is activated. Follow the Machine Activation / Time Extension - NGC procedure.

When the robot has connected with the machine, a yellow message saying Robot Activation Successful should appear at the bottom of the Haas screen.

6

Release the [E-STOP] and press RESET to clear the alarms. 

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

 Note: The robot in setup mode can only be handle jogged while the F2 button the RJH is pressed. See Setup/Run mode section below.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Move the robot to an accessible location to install the grippers.

Jog J6 to 0.0000 position. The location hole should be centered on top.

Note: Press [E-STOP] before working on the robot.

Gripper Installation

1

Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

2

Jog the robot so that you can easily access the end joint. This will allow for easier installation of the grippers assembly.

Install the gripper mounting plate [1] to the end joint of the Cobot using the 4 SHCS and washers [2]. 

Note: Make sure that the mounting plate has the correct orientation when installing it. The mounting plate should be aligned so that the electrical connector [3] is at the top of the bracket as shown in the image. 

Note: There is an extra bore in the face of the end joint. This hole is slightly larger than the 4 fastener bores, and should not be used to mount the grippers.

3

Install the HC5 gripper assembly [1] to the gripper mounting plate using the 2 SHCS and washers [2].

Make sure that the air hose fittings [3] are oriented towards the top of the mounting plate as shown in the image.

4

Route the (x2) air lines from the gripper to the same color coded fitting on the dual air solenoid assembly. 

Secure the air lines by wrapping them in cable conduit. Use the velcro straps to attach the cable conduit to the Cobot. Make sure there is enough slack so that cables aren't strained when Cobot is fully extended.

Insert the input air hose to the used solenoid's fitting [1]. 

Make sure the plug is installed onto the unused solenoid's fitting [2]. 

Verification

Test the E-stop:

  • Press each E-STOP button located on the Haas Pendant, RJH-XL, and Cobot Teach Pendant. Make sure the machine generates 107 EMERGENCY STOP alarm.  If the E-STOP button does not generate a 107 EMERGENCY STOP alarm verify the wiring. Load the latest configuration files to enable the RJH-XL.

Test the Robot Safety Device:

Make sure that there is an E-STOP or light curtain triggered icon on the Haas pendant when the robot safety device is triggered. 

  • Fence - Insert the key into the interlock, verify that the two red LED lights in the front of the interlock are OFF. Remove the key from the interlock, verify that the two red LED lights are ON. 
  • Area Scanner - Step inside the protective field, verify that the red LED lights up on the area scanner. Step outside the protective field, verify that the green LED lights up.
  • Light Curtain - Interfere the light curtain beams, verify that the light curtain triggered icon appears on the Haas pendant. Press [RESET]. Step outside of the light curtain beams, verify no icon appears on the Haas pendant. 

NOTE: If the light curtain triggered icon does not show, verify wiring, alignment and factory setting: 2191 [694:] LIGHT CURTAIN TYPE is set to LC_TYPE_1.

Test the Operation of the Grippers:

  • Verify that both grippers clamp and unclamp correctly.
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • Press [F2] to clamp/unclamp the Finish Gripper.
  • Press [F3] to clamp/unclamp the Raw Gripper.

Test the Remote Jog Handle:

  • Undock the Remote Jog Handle
  • Press the [HANDLE JOG] button. 
  • Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.
  • On the Remote Handle Jog press the Joint button to go into the Joints Coordinates.
  • Move the robot to a safe location.

IMPORTANT: If a yellow warning message appears saying "Please activate Light Curtain or Cell Safe" while trying to job the robot, verify the safety parameter was applied by re-uploading the configuration files from HBC. 

Verify Safe / Run Mode Operation

All Haas CNC machines are equipped with a key switch on the side of the control pendant to lock and unlock setup mode. The robot will have the following behaviors depending on what mode is selected. 

  • When the Haas control is in Run mode, mode 1, triggering the robot safety device stops all motion. This motion can not be started until the robot safety device is no longer triggered.
  • When the Haas control is in Set up mode, mode 2, speed limited motion such as jogging an axis of the robot can be performed in order to program a robot's path of motion, pick up position, set a robot's tool center point, (an offset), load and pick up parts from the spindle or part holder in the machine, etc. The programmed path will also be able to be run slowly to prove out the programmed path of the robot. The robot in setup mode can only be handle jogged while the F2 button the RJH is pressed.

Haas Robot - Quick Start Guide

After installing the robot, set up a job following the procedure below.

Haas Robot - Quick Start Guide

Disable the Robot

To disable the robot to run the machine in stand-alone mode. Press [SETTING]. Change the following Settings:

  • 372 Parts Loader Type to 0: None
  • 376 Light Curtain Enabled to Off