There are several components packaged with the cobot:

1. Cobot Arm (Mechanical Unit Box) [1]
2. Cobot Control (Controller Box) [2]
3. Control Box to Arm Signal Cable (Accessories Box)
4. Teach Pendent Tablet and Cable (Accessories Box)
5. Cobot Mounting Hardware

 Important: Verify you received these components during unboxing and save all documents provided with the cobot. These documents should be stored where they can be found at any point over the life of the cobot.

Below are the components that need to be installed in order to integrate the cobot to the Haas Machine. These will be delivered in additional packaging:

1. Mounting Pedestal [3]
2. Parts Table and Template [4] 
3. Part Flip Station [5]
4. Electrical Interface Kit [6]
5. Safety Device [7]
6. Gripper Assembly [8]
7. Pneumatic Supply Assembly [9]
8. Permanent Anchoring Hardware

 Note: Other components are included with a cobot such as cables and anchoring provisions. Refer to HBC for a complete list of items that were ordered.

Place the cobot pedestal [1] in position.

Use a lifting strap to position the cobot arm [2] onto the pedestal.

Orient the cobot so that the electrical connector coming out of the base of the cobot [3] is pointed to the left as shown in the image.

 Note: The electrical connector indicates the travel limit for Joint 1. Having it oriented correctly will make setting up a job much easier.

 Note: The pedestal has many different mounting holes to accommodate the different size cobots. The HC20KG-F should be mounted in the hole pattern shown in red [5]. 

Fasten the arm to the pedestal using the M8 SHCS and washers [4] provided in the cobot packaging.

Torque the mounting SHCS according to RD0026 - Haas Fastener Torque Specification

Place the cobot control box [1] next to the pedestal [2].

The cobot signal cable needs to be connected from the control box to the arm. Connect the male end of the cable to the control box port [3] and connect the female end of the cable to the base of the cobot arm [4].

Warning: Make sure that the connectors are oriented properly to avoid damaging any pins on the connector. Verify that both ends of the cable are securely connected before powering on.

The ground cable also needs to be connected between the cobot arm base [1] and the cobot control box [2].

The grounding locations are shown in the image. The control box ground terminal is located above the cobot signal cable that was installed in the previous step.

Note: The larger eyelet ring connector should be connected to the control box terminal [2].

Connect the teach pendent tablet to the control box.

Connect the male end of the teach pendent cable [1] to the control box terminal on the right side.

Connect the other end of the teach pendent cable to the teach pendent holster [2].

Once these connections are made and the teach pendent, control box, and cobot arm are all installed, the cobot control box can be connected to incoming power. Incoming power for the HC20KG is supplied from the Haas Machine. Continue to the Electrical Installation section below for more details.

Take the Haas spec plate [1] and place it on top of the cobot control box [2] as shown in the image.

Use double sided tape to secure the spec plate in position.

The spec plate includes:

• Haas Serial Number
• Model Type

 Warning: If the Haas Machine is powered ON, disconnect the 220VAC power cable from the electrical interface box. 

Place the electrical interface box on the enclosure of the Haas Machine.

Feed the other end of the robot signal cable 33-1542 coming from the front of the interface box and the gripper solenoid cable 33-1548 through the right side of the cobot control box [1].

Open the control box and connect the RJ-45 cable to port CD38A [2] located in the upper right corner of the PCB on the back wall of the control box.

Pull enough slack of the robot signal and gripper solenoid cable so that they can be connected to the IO/Safety PCB [3] located on the inside of the control box door.

See the next step for where to connect the robot signal and gripper cable to the IO/Safety PCB.

The cobot control box will come with jumpers on the safety/IO PCB. These jumpers will have to be moved in order to connect the robot signal cable to the safety/IO PCB.

The jumpers will be connecting the following pins on CRMC24:

• 24VEXT to 24V-2 (p1 to p2) [1]
• 0VEXTA to 0V (p18 to p19) [2]
• EXEMG1 to 24V-2 to FENCE1 (p4 to p5 to p6) [3]
• EXEMG2 to 0V to FENCE2 (p21 to p22 to p23) [4]

 Note: All terminal locations are labeled on the PCB as shown in the image.

Disconnect the jumper from {EXEMG1 to 24V-2 to FENCE1} and the jumper from {EXEMG1 to 24V-2 to FENCE1}.

Move the jumpers so that they are connected in the following way on the CRMC24 terminal:

• 24V-2 to EXEMG1 and leave FENCE1 disconnected (p3 to p4 and FENCE1 disconnected) [1]
• 0V to EXEMG2 and leave FENCE2 disconnected (p20 to p21 and FENCE2 disconnected) [2]

Use the wago connectors provided in the integration kit. Connect the FENCE2 pin of the jumper [3] to one wago connector [4]. Then connect the FENCE1 pin of the jumper [5] to the other wago connector [6].

Connect the red jumper wire 33-1553 to the safety/IO PCB.

Connect one end of the red jumper wire to the DOSRC1 (p6) [1] on CRMC20.

Connect the other end of the red jumper wire to the wago connector [2]. Use the wago connector that is connected to the blue wire labeled FENCE1.

 Note: The label on 33-1553 is labeled pin 3. Use the wago connector since the other end of the blue FENCE1 wire is connected to pin 3 [3].

Route the robot signal cable to the safety/IO PCB. Connect the cable to the safety/IO PCB as shown in the image:

Connections to CRMC24

• GREEN wire to 24V-2 (p5)
• GREY wire to FENCE1 (p6)
• BROWN wire to 0V (p22)
• RED wire to FENCE2 (p23)

Connections to CRMC19

• VIOLET wire to SFDI11 (p1)
• BLACK wire to 24V-2 (p2)
• YELLOW wire to SFDI12 (p3)
• WHITE wire to 24V-2 (p4)
• BLUE/RED wire to SFDI21 (p5)
• BLUE wire to 0V (p6)
• PINK wire to SFDI22 (p7)
• GREY/PINK wire to 0V (p8)

Route the dual gripper solenoid power cable 33-1548 [1] to the safety/IO PCB. Make the following connections:

Connections to CRMC20

• BLACK to DO01 (p1)
• RED to DO03 (p2)
• WHITE/BLACK & WHITE/ORANGE to 0V (p5)
• ORANGE to DO02 (p7)
• BROWN to DO04 (P8)
• WHITE/BROWN & WHITE/RED to 0V (p11)

Once everything is connected inside the control box, connect the 220VAC power cable coming from the interface box on the Haas machine.

The power cable is connected to the 4 pin connector on the right side of the control box [1].

 Note: The connector is keyed. Make sure you have the connector oriented correctly before trying to connect to the control box. 

Secure the connector by tightening the threaded collar.

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: 

 Note: The light curtains also come with mounting plates. These mounting plates should be anchored to prevent the light curtains from being misaligned. 

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: 

Power ON the Haas Machine. Once the machine is booted up, turn the main breaker on the cobot control box [1] to the ON position.

Power on the teach pendent tablet by pressing the button on the side [2] as shown in the image.

Once the teach pendent powers on, swipe up from the bottom to unlock the tablet and get to the home page as shown in the image [3].

Swipe up to view the list of apps installed on the teach pendent.

Press on the Tablet TP app icon [1] to open the teach pendent application.

If the control box was just powered on then you will see the loading screen [2] indicating that the control box is still booting up. 

 Note: It may take a 1-2 minutes for the control box to fully boot up.

Once the application boots up there will be a Payload Confirmation window that pops up.

The cobot will list the payload, center of mass, and inertia that is detected. Since the cobot is not yet connected to the Haas machine and there is no grippers installed, there should be no payload detected.

 Note: Small deviations in payload on the payload confirmation pop up will not impact the cobot. If you notice a difference in payload on this screen still continue.

Check that the listed payload seems accurate and then press [Yes] [2] to continue.

Once the payload confirmation is successful you will be taken to the main menu. If there are any alarms present they will show up near the top of the screen [3]

Press [Reset] [4] to clear any alarms. 

 Note: Refer to section 8.1 Cobot-F Troubleshooting for more details on any alarms that you can't clear.

When all alarms are cleared the indicator light on joint 1 [1] of the cobot arm will turn green as shown in the image.

Press the Robot Operation button at the bottom of the screen [2].

From there click the jog tab and use the sliders [4] to ensure that the cobot can jog.

 Note: Keep the override low so you don't get big movements when jogging. The image shows the override at 10%.

Take a full system and image backup from the cobot control box.

Insert a usb into the UD1 port on the right side of the control box [1]. (Next to the pendent signal cable.

Follow the video for how to take the system and image backup.

1. Press on the hamburger menu on the upper left corner.
2. Navigate to the File Backup option under the Utility submenu.
3. Select the Front Panel USB (UD1) option and press next step at the bottom.
4. Select Create Directory and then confirm the directory name you wish to use.
5. Press next step at the bottom. Enable the teach pendent by clicking the TP button on the top right of the screen. Then select the Full System and Image Backup option.
6. Wait for the files to copy and for the SYST-360 - Please cycle power alarm to generate.
7. Press the hamburger menu and go to the Cycle Power option. Select Cold Start.
8. Wait until you get the SYST-213 - User Cycle Power warning. Then power OFF the control box circuit breaker and wait 15 seconds before turning it back ON.

Wait until the cobot boots back up and all alarms are reset before continuing to the next step.

 IMPORTANT: Make sure to change the teach pendent back to Disabled mode [1]. TP disabled mode is when there is a line through the rectangle as shown in the image.

Move to the Haas control pendent to configure the Haas machine to integrate with the cobot.

Press [DIAGNOSTICS] and navigate to the Factory tab and press [E-STOP]. Verify that the below parameters are set correctly.

• 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
• 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
• 2195 [:] Enable Right Door Fully Open Switch to TRUE
• 2196 [:] Enable Left Door Fully Open Switch to TRUE
• 2192 [:] Light Curtain Trigger Threshold to 0
• 2128 [:] Pallet Pool Type to 0

 Note: These parameters are needed to enable the light curtains and the door fully open confirmation switches.

Press the [SETTING] and verify that the below settings are set correctly:

• 372 Parts Loader Type to 3: Robot
• 375 APL Gripper Type to None
• 376 Light Curtain Enabled to On

 Note: You must have the light curtains enabled to integrate the cobot with the Haas machine. Without setting 376 enabled, the control will display a message asking you to activate the light curtain.

Once these settings are set, you can now view the APL and Robot tabs inside the Current Commands menu.

Press [CURRENT COMMANDS] and navigate to the Devices -> Robot -> Setup menu.

Press [E-STOP] on the Haas pendent.

Then press [F1] [1] to establish a connection to the cobot.

Wait for a few seconds for the Haas machine to connect to the cobot.

 Note: If this is the first time the Haas machine has connected to the cobot you will see the Activation popup on the Haas pendent.

If the cobot already has been activated, then you will know that you are connected based off the robot icon on the lower right corner of the Haas icon. A green icon indicates a connection. A red icon indicates the cobot isn't currently connected [2].

If you need to activate the cobot, then you will get the popup similar to the image.

The popup will have the following displayed:

1. Software Version of the Haas Machine
2. MAC Address of the cobot connected [1]
3. Generated Code

You will need to locate and enter the following to successfully activate the cobot:

1. F Number [2]
2. Unlock Code [3]

Note: The unlock code can only be obtained through the Robot Activation transaction on HBC.

Finding Cobot F Number:

There are 2 ways to locate the F number on a Cobot:

1. The placard on the base of the cobot below Joint-1 [1]
2. The placard on the front door of the control box above the spec plate [2]

Getting Unlock Code through HBC:

The unlock code can only be obtained through HBC by a Haas Certified Technician.

On HBC press on the Service tab [1] and then find the Robot Activation transaction [2] on the left side menu.

Complete all the fields on the various steps in the activation process. 

 Note: You will need information included on the activation popup as well as the serial numbers of both the Haas machine, Cobot package, and the F-number to obtain the Unlock code.

Enter the F-Number [3] and the Unlock Code [4] on the popup in order to activate the cobot.

After activation is successful, press [F1] to connect to the cobot again if needed.

Wait for the robot icon to turn yellow or green [1]. Then release [E-STOP] and clear the alarms by pressing [RESET].

Look at the indicator light on Joint-1 on the cobot arm [2] and verify that it is green as well.

Start by setting the Number of Grippers field [1] to either 1 (for single gripper) or 2 (for dual gripper).

Configure the gripper Clamp/Unclamp outputs as listed below.

For the Raw Gripper [2] (Gripper 1):

• Clamp Output = 2 
• Unclamp Output  = 1
• Clamp Delay = 0.0
• Clamp Type = Outside

For the Finish Gripper [3] (Gripper 2):

• Clamp Output = 4
• Unclamp Output = 3
• Clamp Delay = 0.0
• Clamp Type = Outside

 Note: These fields can be reconfigured depending on the application. This is just to confirm that the grippers work as intended.

The Gripper Net Mass field needs to be completed. This can be completed by going through the payload estimation process detailed below.

Press [ENTER] to bring up the Mass and Center of Gravity popup [1].

Press [PAGE UP] to start the Payload Estimation process.

 Note: You may see a Payload Confirmation Required popup when you try to set the payload. Press [Y] if the payloads are correct [2]. They should be zero if this is the first time setting payloads.

Note: When starting the payload estimation for the grippers, make sure you start with nothing attached to the end of joint-6 on the arm.

Follow the instructions on the popup:

Step 1 - Pre-Position: Make sure that the cobot is in a position so that it can move joints 5 and 6 freely without contacting anything.

If needed, use the RJH-XL to jog the cobot to an open area.

Step 2 - Clamp/Unclamp Grippers: Follow the prompt to unclamp the grippers assembly. 

Even though there are no grippers on the arm, you need to press [F2] [2] if it says that the action is Pending [1]. It will show Completed when the action is done.

Once the action is completed press the right arrow [3] to continue to step 3.

Step 3 - Stage For Estimation: During this step, the cobot will automatically move to position the end of Joint-6 to point straight down like it is hanging [2].

Press [F2] [1] to allow the cobot to position itself. Wait for the action to be completed [3] and then press the right arrow [4] to move to the next step.

Step 4 - Start Estimation: Before starting the estimation process you need to attach the gripper assembly to the end of Joint-6.

Fasten the adapter plate [1] to the end of Joint-6 using the 7 mounting bolts and washers [2]. 

 Note: Make sure the hole pattern is matching the mounting surface where the alignment hole [3] is not inline with a bolt.

Fasten the gripper assembly [4] to the adapter plate using the 8 SHCS [5].

Once fastened, press [F2] [6] to start the estimation. Once the estimation is is done the [Measure] button will become available. Press [Insert] [7] to record the estimated payload.

Verify that the cobot can be jogged from the Haas control. Also verify that the hand guide mode can be enabled from the RJH-XL.

 Important: If the gripper assembly is installed on the arm and the mass/payload is not configured on the control you may run into issues jogging or with hand guide mode. See the section below for how to setup gripper mass.

To jog the cobot using the JRH-XL, navigate to the Jogging tab [1]. Press [HANDLE JOG] and then press [CURRENT COMMANDS] to switch to jogging mode.

Press [Joint] [2] for joint mode jogging and jog each joint to the zero position on the RJH-XL. Once each joint is at 0.000 check that the arrow marks [3] on each joint are aligned on the arm.

 Note: If the arrows are not aligned, that means that the cobot zero position needs to be remastered. Refer to the maintenance chapter for how to remaster the cobot.

To enable Hand Guide mode, use the RJH and press on the [MECH] option on the bottom [1].

That will bring up the page showing the Gripper and Cobot options. For guide mode press the [COBOT] option [2].

To switch to hand guide mode press [GUIDE] [3] on the bottom of the screen.

Verify that you are in guide mode by checking that the indicator light on Joint-1 is blinking green [4]. This indicates that the cobot can be hand guided.

Push the arm and make sure that it can be manipulated by hand.

 Note: If you encounter issues with the hand guide mode verify that the grippers are unclamped, and that the payload for the grippers is set.

The cobot parts table comes disassembled. It will need to be assembled when the cobot is installed. Refer to the link below for instructions on how to assemble the parts table.

The yellow brackets [1] are meant to be anchored down so that the parts table can be fixed in position. Refer to Cobot - Anchoring document for how to anchor the various components in position.

 Important: It is recommended to test a complete loading job prior to placing any anchors. Once the setup and positioning of the pedestal, parts table, part flip, and light curtains is verified, anchor these components in their positions.

The part flip station comes disassembled. It will need to be assembled when the cobot is installed.

The part flip station can be anchored so it can be fixed in position. Refer to Cobot - Anchoring document for how to anchor the various components in position.

 Important: It is recommended to test a complete loading job prior to placing any anchors. Once the setup and positioning of the pedestal, parts table, part flip, and light curtains is verified, anchor these components in their positions.

The part flip station consists of a weldment base post [2], the extension bracket [1], and the part flip bracket [5].

Use two of the 1/4-20 x 3/4" FBHCS [3] to fasten the extension bracket [1] to the weldment base post [2].

Use the other two 1/4-20 x 3/4" FBHCS [3] to fasten the part flip bracket [5] to the extension bracket [1] as shown in the image.

Refer to the layout section below for where to position the part flip station relative to the cobot pedestal and the parts table.