Tal Brabo Tr10-5 Operating Manual Eng v1

Operating Manual
TR 10-5
Version 1
The information in this manual is subject to change without notice. Any liability and warranty for the accuracy
of this information is excluded.TAL reserves the right to make changes at any time. TAL shall not be liable for
any incidental or consequential damages to persons or property arising from the use of this manual and products
described herein.
Additional copies of this manual may be obtained from TAL. The original language for this publication is English.
Any other languages that are supplied are translated from English.
Replication, distribution and / or editing of this document and the use and distribution of its content is prohibited
unless explicitly permitted. Violation obligates compensation for damages. All rights reserved in case of the issue
of a patent, utility patent or design patent.
Copyright © 2017 TAL Manufacturing Solutions Limited.

This page is intentionally kept blank
Table of contents
Table of contents
1 About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Intended users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Important safety notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Conventions used in this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Acronyms and initialisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Language of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Copyrights and trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.9 Manufacturer’s address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.10 Customer support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.11 Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Applicable safety standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 General safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Safety symbols on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.1 Safety symbols on the robotic arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.2 Safety symbols on the robot controller and teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.7 Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.8 Workspace and safety zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.9 Safety systems on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.10 Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.11 Moving the robot without power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.12 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Overview of the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Robotic arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.3 Robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 Central Processing Unit (CPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.1 Backlit display on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.2 I/O channels on the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
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Copyright 2017 TAL Manufacturing Solutions Limited. All rights reserved.
Table of contents
3.3 CAN 16 I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.4 Removable storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6 Recommended tightening torque for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.7 Location of the name plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.8 Payload and centre of gravity of the end-effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.9 Centre of gravity of the robot during lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Transport notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Unpacking and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Lifting the robotic arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 Lifting the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.6 Installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 Installation site and area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 Recommended tightening torque for screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9 Mounting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 Connecting the robotic arm and the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.10.1 Connecting the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10.2 Connecting the encoder cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.10.3 Connecting the teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.10.4 Connecting the earthing wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.10.5 Connecting the robot controller to the main power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.10.6 Checking the connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.11 Mounting the end effector on the robot flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.12 Repacking and storing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Safety precautions before switching ON the robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Switching ON the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Overview of the teach pendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Navigation bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 User levels and rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Logging in to the teach pendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.6.1 Switching from Manual to Auto mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.6.2 Switching from Auto to Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6.3 Switching to Idle mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
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5.7 Homing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.8 Robot program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9 Structure of a Robot program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10 Creating a new program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.11 Program instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.11.1 MOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.11.2 POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.11.3 WAIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.11.4 SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.11.5 IF....ELSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.11.6 LOOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.11.7 HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.11.8 JUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.12 Program structure editor instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.13 Saving a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5.14 Opening a saved program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.15 Editing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.16 Testing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.17 Running a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.18 Pausing a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.19 Resuming a program after a pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.20 Stopping a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.21 Jogging the robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.22 Configuring inputs and outputs, I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.23 Turning ON and OFF the inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.24 Defining the variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5.25 Restarting the robot after a fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5.26 Stopping the robot in an emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5.27 Restarting the robot after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5.28 Closing the current program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5.29 Deleting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.30 Managing errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.30.1 Viewing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.30.2 Downloading the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5.31 Setting the home offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.32 Setting the U-axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.33 Setting the tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.34 Tool calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.35 WORLD co-ordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.36 Tool Centre Point (TCP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.37 Defining user frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.38 Basic programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
III
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Table of contents
5.38.1 Motion type - Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

5.38.2 Motion type - Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5.38.3 Motion type - Circular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.38.4 Motion type - Rectangle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5.38.5 Teaching a point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5.38.6 Using the Merge option and teaching a fillet profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5.39 Switching user levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5.40 Exiting the teach pendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.41 Restarting the teach pendant application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5.42 Viewing the teach pendant application details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
5.43 Upgrading the teach pendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5.44 Changing the password of the teach pendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
5.45 Shutting down the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 General safety and precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Tools required for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Recommended spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 Maintenance and lubrication schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Quarterly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Half-yearly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.1 Common errors and solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.2 Fault list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7 Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8 Warranties and certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Product warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
IV
Copyright © 2017 TAL Manufacturing Solutions Limited. All rights reserved.
1 - About this documentation
1 About this documentation
1.1 Introduction
This documentation is about the TAL BRABO TR 10-5 five axis articulated
robot that is intended to be used for industrial applications.
The instructions published in this manual must be strictly followed. The manual
must be stored in such a place where it can be reached easily by the user.
The manual is a part of the robot.
1.2 Intended users

This manual is intended for the operator and integrator of the robot. The users
must have a good understanding and training of mechanical and electrical
systems. They must also be familiar with elementary concepts of
programming.
The operating and service personnel who operate and maintain the robot must
be properly trained and authorised by TAL. Furthermore, they must
understand the content of this operating manual and know how to find the
relevant information.They also must understand the safety equipment of the
robot and follow the environmental and safety rules of the country where the
robot is installed.
1.3 Important safety notice

This manual contains safety information pertaining to the robotic arm, the robot
controller, and the teach pendant. Take care of the following points while
working with the robot:
▪ Do not operate the robot without a safety enclosure or safety fence.

The robot is not designed be operated in collaboration with humans
without a safety enclosure or fence.
▪ Do not touch the robotic arm or enter the robot workspace when the
robot is switched ON.
This manual does not include information about designing, installing, and
operating a complete robot application. For safety information about the
complete system, refer to the technical documentation compiled by the
integrator of such a system.
Before you operate the robot, read the information given in this manual,
specially the safety instructions. To ensure the safety of personnel and
equipment, it is particularly important that all of the safety instructions are
followed.
Operating Manual V1 TAL BRABO 1-1

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1.4 Conventions used in this manual

These conventions are used in this manual:
Convention Explanation/Example
Page number 1-4 means Page 4 of Chapter 1
Chapter number Chapter 1, 1.1 or 1.1.1 (Up to three heading
levels)
Figure number Fig. 3-12 means Figure 12 of Chapter 3
Call-outs in figures The call-outs are identified in the legend or the
text related to the figure.
This symbol indicates hints and
supplementary information that are useful to
know.
This symbol in a procedure indicates the end
■
of the procedure.
1.5 Terminology
Auto mode The mode of the robot in which the robot can perform
the operations automatically based on a set of
instructions in the robot program.
CE marking The marking on the robot, when accompanied by the
EC declaration of conformity by the manufacturer,
that guarantees that the machine conforms to the
essential health and safety requirements of the
various standards and directives of the European
Union in respect of machinery in general.
Frame Frame is a co-ordinate system which is used to define
positions and orientations.
Hazard A possible dangerous or harmful situation.
Jog Jog or jogging is the manual movement of the robot
using the controls in the teach pendant.
Manual mode The mode of the robot in which the operations such
as jogging the robot, homing the robot, creating a
program, and editing a program can be done.
Residual risk The remaining risks after protective measures have
been taken.
Robot controller The robot controller controls the robotic arm. The
robot controller consists of a cabinet that houses the
central processing unit, power supply, I/O, and data
storage modules.
Robot program A robot program is a set of commands to make the
robot perform a sequence of tasks.
Robotic arm The robotic arm is a mechanism consisting of
interconnected set of links and powered joints with
several degrees of freedom.
1-2 TAL BRABO Operating Manual V1

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Teach pendant The teach pendant is a device with a touchscreen,

used to control the movements of the robotic arm. The
teach pendant has an application that the user can
use to create new robot programs, edit, or run existing
programs.
Tool A device mounted on the robot flange to allow it to
perform specific tasks, such as cutting, gripping, or
welding. The tool is the robot’s last link.
Tool centre point The central axis of the tool movement. The tool centre
point (TCP) is the point in relation to which all robot
positions are defined.
Workspace Workspace defines the boundary of space within
which a robot can perform operations. This boundary
is defined by the distance from the centre of the robot
to the fullest extension of the robot arm.
1.5.1 Acronyms and initialisms

AC Alternating Current
CAN Controller Area Network
CPU Central Processing Unit
DC Direct Current
DIN Deutsches Institut für Normung (German Institute for
Standardisation)
EMC ElectroMagnetic Compatibility
EtherCAT Ethernet for Control Automation Technology
FAT File Allocation Table
I/O Input/Output
IP Internet Protocol
PE Potential Earth
UPS Uninterruptible Power Supply
USB Universal Serial Bus
1.6 Disclaimer
Every effort has been made to keep the information contained within this
manual current and accurate as of the date of publication. Nevertheless,
discrepancies cannot be ruled out. Any liability and warranty for the accuracy
of this information is excluded. The information in this manual are reviewed
at periodical intervals.
TAL reserves the right to make changes at any time.

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1.7 Language of instructions

The operating instructions were originally created in English. All translations
are based on the language of the original manual.
1.8 Copyrights and trademarks

The copying, distribution and utilisation of this document in printed or electronic
form as well as the communication of its contents to others without expressed
authorisation is prohibited. Violation obligates compensation for damages. All
rights reserved in case of the issue of a patent, utility patent or design patent.
1.9 Manufacturer’s address

TAL Manufacturing Solutions Limited
PDO Building, TATA Motors Campus,
Chinchwad, Pune – 411 033,
Maharashtra
India
Phone: +91 20 6613 5509
Fax: +91 20 6613 5578
Internet: http://www.tal.co.in
1.10 Customer support

If you have a question, suggestion, or concern regarding the product or its
implementation, send us an email at:
[email protected].
Or call us on the toll-free number,
18002670103 (Monday to Friday – 9 a.m. to 6 p.m. IST)
Our customer support representative will be glad to assist you.
1.11 Revisions
Revisions Date Changes
V1 June 2017 First release

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2 - Safety
2 Safety
2.1 Intended use

The TAL BRABO robot is intended to be used in an industrial environment for
applications such as picking and placing objects, sorting, welding, applying
sealants and so on. The robot is intended to be used only with the necessary
safety precautions as mentioned in this manual and in accordance with the
laws and regulations applicable in the country where the robot is used.
The robot may be used along with other robots or industrial automation
systems after a comprehensive risk and hazard analysis of the complete
system is carried out and the system is without any significant hazards. The
robot must never be operated without a safety enclosure or fence.
WARNING
Moving robotic arms.
Risk of severe injury or death.
– Do not operate the robot without a safety
enclosure or safety fence.
– Do not touch the robotic arm or enter the robot
workspace when the robot is switched ON.
Any other use is not considered to be consistent with the intended purpose
and the manufacturer or supplier is not liable for any damage resulting
therefrom. This includes, but is not limited to:
▪ Using the robot without performing a risk assessment of the complete

system.
▪ Operating outside the permissible operating parameters.
▪ Operating the robot in potentially explosive environments.
▪ Using the robot in medical and life-critical applications.
▪ Operating the robot in environments involving high heat and vibration.
▪ Operating the robot in environments involving strong magnetic fields.
▪ Using the robot for outdoor applications.
If you have questions about the suitability of the robot for a particular
application, contact TAL customer service centre or a TAL authorised
representative.

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2 - Safety
2.2 Limitation of liability

The information given in this manual does not warranty that the robot will not
cause injury or damage even if all safety instructions are complied with.TAL
declines any liability or responsibility, directly or indirectly, for any damages
to equipment and properties or for injuries to persons arising from the improper
operation of the robot and connected equipment.
The industrial robot may only be used in accordance with the intended purpose
and safety regulations of the country in which the robot is installed. The robot
may be operated only by technically- qualified and safety-conscious personnel
who are aware of the risks involved.No modifications on the robot and
connected equipment may be carried out without approval from TAL.
Additional components such as tools may be integrated to the robot or the robot
itself may be integrated to a complete automation system. The owner or
integrator is solely liable for any damage these components may cause to the
robot or to other property.
TAL disclaims all responsibility for any accident caused by personnel who do
not obey the instructions for use. TAL is not liable for any accidents caused
by changes or removal of any of the installed safety systems.
2.3 Applicable safety standards

The TAL BRABO robot conforms to the following standards:
▪ ISO 10218-1: Safety requirements for industrial robots - Part 1: Robots

▪ ISO 10218-2: Safety requirements for industrial robots - Part 2: Robot
systems and integration.
▪ IEC 60204: Safety of Machinery, Electrical equipment, General
requirements.
▪ IEC 61439: Low Voltage switch gear and control gear assemblies.
▪ IEC 62208: Empty enclosures for low voltage switch gear and control gear
assemblies - General requirements.
▪ ISO 7000: Graphical symbol for use on equipment - Index and synopsis.

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2 - Safety
2.4 General safety information

This section provides information about the general safety information of the
robot and its usage.
General notes
▪ The safety instructions given in the operating manual must be observed.
▪ The accident prevention rules and regulations in force at the operating site
must be observed
▪ The personnel working on the robot system must not wear loose clothing
or jewellery which may get entangled with the robot during its operation.
▪ It is the obligation of the owner to allow only persons with sufficient
knowledge of the technical and safety aspects of the robot to work at the
operating site. The safety awareness of the operating personnel must be
inspected at regular intervals.
▪ The working space of the robot must be safeguarded using enclosures or
fences. Access to the working space of the robot during operation must
be prevented by safety systems such as safety-interlocked door switches,
light curtains, or sensitive mats. All normal operations must be executed
from outside the safeguarded space.
▪ The safety devices or circuits must not be modified, bypassed, or changed.
▪ The robot must not be modified. Modification of the robot may create
unforeseen hazards.
Integration to other systems

▪ The information in this manual covers functions concerning the robotic
arm, robot controller, and the teach pendant. The information does not
cover how to design, install, and operate a complete system, nor does it
cover all peripheral equipment, which can influence the safety of the total
system.
▪ The safety instructions provided by the integrator and the supplier of other
equipment in the integrated environment must be observed.
▪ The integrator of the complete system must make sure that all circuits used
in the emergency stop function are interlocked in a safe manner, in
accordance with the applicable standards for the emergency stop function.
▪ Combining different machines might increase hazards or create new
hazards. The integrator must do an overall risk assessment for the
complete installation and make sure that the system complies with EC
machinery directive.
▪ When the robot is integrated to work in coordination with other industrial
equipment, always test the program to avoid overlapping of equipment
workspaces.
Safety during installation and service

▪ Make sure to install the robot and all electrical equipment according to the
specifications and instructions given in the operating manual.
▪ The power connection switch to the robot controller must be outside the
enclosure and at a position that can be easily accessed.
▪ The personnel who install the robot must be trained by TAL for installation.
They must have the knowledge of the relevant standards, directives, and
regulations for installation of the robot.
▪ Make sure the robotic arm has ample space to operate freely.

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2 - Safety
▪ Make sure that safety measures and robot safety configuration

parameters have been set up to protect programmers, operators and
bystanders, as defined in the risk assessment.
▪ Emergency stop buttons must be positioned in easily accessible locations
outside the safety enclosure of the robot.
▪ The robot is not designed to be used in areas with strong magnetic fields.
▪ I/O cables from the robotic arm to the robot controller must not be modified.
If the required length of the cables are more than the length of supplied
cables, contact TAL.
Safety during operation

▪ All normal operations must be executed from outside the safety enclosure
of the robot.
▪ If the software prompts a fatal error, immediately activate emergency stop,
write down the conditions that led to the error, find the corresponding error
codes on the log screen, and contact TAL.
▪ Before entering the robot workspace, the main power switch must be
turned OFF and secured with a padlock.
▪ The motors of the robotic arm and certain components inside the robot
controller reach high temperature during continuous operation. These
parts must only be touched after the robot is turned OFF and the hot parts
have cooled down.

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2 - Safety
2.5 General safety symbols

The following general safety symbols and warning messages with signal words
appear throughout this manual. The signal words indicate different severity
levels. Every safety message consists of a hazard description, its
consequences if not avoided, and how the hazard can be avoided.
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
avoided, could result in death or serious injury.
CAUTION
avoided, could result in minor or moderate injury.
NOTICE
This signal word indicates that the user must pay special attention to
a given procedure or message to avoid property damage.

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2 - Safety
2.6 Safety symbols on the robot

The following safety and warning symbols conforming to ISO 7000 are present
on the robot and connected equipment. Safety stickers must not be removed
from the robot or other equipment. If the stickers are worn out or damaged,
replace them immediately.
2.6.1 Safety symbols on the robotic arm

The following symbols are present on the robotic arm:
▪ Electrical hazard symbol on the base near the power and encoder
connector.
▪ Hot surface hazard symbol on the motor surfaces.
▪ Lifting symbol near the lifting position (eye-bolt) of the robotic arm.
Fig. 2-1 Safety symbols on the robotic arm

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2 - Safety
2.6.2 Safety symbols on the robot controller and teach pendant

The following symbols are present on the teach pendant:
▪ Warning symbol at the rear side of the teach pendant.
The following symbols are present outside the robot controller cabinet:
▪ Electrical hazard symbol near the main switch.
▪ Electrical hazard symbol near the power connection.
▪ Earthing symbol near the power connection.
▪ Electrical hazard symbol on the 230V utility socket cover.
▪ Lifting symbols near the lifting position (eye-bolts) of the robot controller.
Fig. 2-2 Safety symbols on the robot controller and teach pendant

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2 - Safety
The following symbols are present inside the robot controller cabinet:
▪ Electrical hazard symbol on the main power switch.
▪ Hot surface hazard symbol on the heat sink of the drive.
▪ Hot surface hazard symbol on the thermal cut-off device.
▪ Earthing symbol inside the robot controller cabinet.
Fig. 2-3 Safety symbols inside the robot controller
2.7 Risk assessment

A complete risk assessment of the robotic arm, the robot controller, and the
teach pendant has been carried out as per the following requirements and
guidelines:
▪ ISO 10218-1:2011 Robots and robotic devices - Safety requirements for

industrial robots - Part 1: Robots.
▪ ISO 10218-2:2011 Robots and robotic devices - Safety requirements for
industrial robots - Part 2: Robot systems and integration.
The risk assessment is carried out considering that the robot is operated within
a safety enclosure or fence.
If the robot is used along with other robots or industrial automation systems,
a risk assessment of the complete system must be done by the integrator of
the system. The system integrator must issue a declaration of conformity for
the complete system in accordance with European Machinery Directive. The
owner or integrator must make sure that the applicable safety laws and
regulations in the country concerned are observed and that the safety devices
necessary to protect people working with the robot system are designed and
installed correctly.

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2 - Safety
2.8 Workspace and safety zone

The robot is heavy and powerful, even at low speed. Operators must be aware
that the robot can make unexpected movements. A pause (stop) in a pattern
of movements may be followed by a movement at high speed. Operators must
also be aware that external signals can affect robot programs in such a way
that a certain pattern of movement changes without warning.
The robot must only be operated inside an enclosed space or fence. The
enclosure must be with sufficient safety systems or locked to prevent access
of personnel into the enclosure while the robot is in operation. If locked, the
keys must be handled by authorised personnel. When entering into the robot's
workspace, the applicable safety regulations of the country concerned must
be observed. The safe zone for the operator is outside the enclosed space.
WARNING

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2 - Safety
The workspace of the robot is as shown in the following figure:
Fig. 2-4 Workspace of the robot (All dimensions are in mm)

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2 - Safety
Take care of the following guidelines when you design the workspace of the
robot:
▪ It is recommended to have an enclosure or fence with an area of at least
4 sq. m (2 m x 2 m) and a height of 1.8 m so that the operator has enough
space to work with the robot inside the enclosure.
▪ The closest wall must be at least 1m away from the base of the robot.
▪ The robot controller and teach pendant must be positioned outside the
enclosure.
▪ The power connection switch to the robot controller must be outside the
enclosure and at a position that can be easily accessed.
▪ If the robot works in coordination with other industrial equipment, design
the workspace such that there is no overlapping of equipment workspaces.
▪ Make sure that the workspace is free of dust, moisture, or flammable
substances.
2.9 Safety systems on the robot

The robot is equipped with safety systems to avoid accidents in case of an
improper usage. Besides, appropriate safety symbols are displayed on the
robot and controller where residual risks still remain. The following safety
systems are present on the robot:
5
3
4
Fig. 2-5 Safety systems on the robot
1. Main power switch on the robot controller

2. Emergency stop button on the robot controller
3. Emergency stop button on the teach pendant
4. Robot controller locks
5. Robot controller key

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2 - Safety
Main power switch

The main power switch (1) is located on the front side of the robot controller.
Use the main power switch to turn ON or OFF the power to the robot controller
and the robotic arm. Before you start any maintenance work on the robotic arm
or the robot controller, turn OFF the main power switch and secure it with a
padlock. Turn OFF the power to the main power switch of the robot controller
and wait for at least three minutes before opening the robot controller cabinet.
A B
Fig. 2-6 Normal and locked position of the main power switch
A. Main power switch - ON position

B. Main power switch - OFF position (locked)
DANGER
High voltage hazard.
Any contact with live parts leads to an immediate
threat to life due to electric shock. Damage to the
insulation or individual components can be lethal.
– Only a qualified and authorised electrician is
allowed to work on electrical equipment.
– Turn off the main power switch and secure it
with a padlock to prevent any unintended
restart of the machine.
– If there is damage to electrical insulation,
immediately turn off the main power switch and
repair the insulation.
– Before you start working on the electrical parts,
make sure that the parts are free of electrical
power.
– Cover or safeguard any other connected
electrical parts.
– Do not bridge any fuses.
– Keep moisture away from live electrical parts.
This may lead to short circuits.

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2 - Safety
Emergency stop buttons

Emergency stop buttons are located on the front side of the robot controller
(2) and on the teach pendant (3). When you push either of these emergency
stop buttons, the robot stops immediately. The emergency stop button on the
controller has a light indicator that glows when the emergency stop is pressed.
The robot cannot be started again unless you reset the button by turning it in
the direction specified on the button.
2 3
Fig. 2-7 Emergency stop buttons
After resetting the emergency stop button, jog the robot to the pre-homing
position and carry out the homing procedure. For more information about pre-
homing and homing procedures, refer to the operation chapter. Use the
emergency switch only in case of an emergency. For normal stop, use the Stop
key on the Program screen of the teach pendant panel. Do not use the
emergency stop as a pause button.
If the robot is used along with other robots or industrial automation systems,
the integrator of the complete system must make sure that all circuits used
in the emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function. Emergency
stop buttons must be positioned in easily accessible places so that the robot
and connected equipment can be stopped quickly.

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2 - Safety
Robot controller locks

Locks (4) on the robot controller prevent unauthorised access to the electrical
and control systems. These locks can only be opened by a special key(5). The
keys must be handled only by authorised personnel who understand the safety
risks involved and the rules and regulations concerning safety of electrical
equipment.
4
Fig. 2-8 Robot controller locks
Do not open the controller cabinet when the main power switch is ON or while
the robot is in operation. Forcefully opening the cabinet door will cut off the
power supply to the controller and the robot.
Enclosures and safeguards

The robot must only be operated inside an enclosed space or fence. The robot
is not supplied with an enclosure. It is the responsibility of the system integrator
to design and implement an enclosure with sufficient safety systems, which
will prevent access of personnel into the workspace of the robot. All applicable
safety regulations of the country where the robot is installed must be observed.

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2 - Safety
2.10 Personal safety equipment

The following personal safety equipment may have to be used while working
with the robot and connected equipment. TAL does not provide these
equipment along with the robot.
Safety goggles
Safety goggles are worn to protect your eyes from dust
and flying particles.
Safety gloves
Safety gloves are worn to protect your hands against
harm caused by friction, abrasion, chemicals or hot
surfaces.
Safety shoes
Safety shoes are worn to protect your feet from falling
objects and against punctures from below.
2.11 Moving the robot without power

The axes of the robotic arm must not be manually moved in the absence of
drive power. The brakes are applied after a power OFF or power failure. If the
robot stops due to a power failure, wait for the power to be restored, and then
jog the robotic arm manually to the pre-homing position. After the robotic arm
is at the pre-homing position, carry out a homing procedure. Refer to the
operation chapter for more information about the pre-homing and homing
procedures.
NOTICE
Moving the robotic arm manually might damage the joints.
It is recommended to use an uninterruptible power supply (UPS) so that the

robot does not stop in between a process, especially while working in
coordination with other industrial systems.

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2 - Safety
2.12 Residual risks

Although the robot is designed in compliance with the current European
Machinery Directive, and subjected to a comprehensive residual risk analysis,
some residual risks still remain. The residual risks are marked with appropriate
machine-specific safety symbol stickers. The potential risks that could occur
during the different phases of the robot’s service life are listed below:
DANGER
power.
electrical parts.
DANGER
Fire hazard.
Risk of severe burns due to fire.
– Do not keep any flammable items in the robot
workspace.
– If any electrical insulation is damaged, repair
the insulation or replace the parts.
– Use a carbon dioxide extinguisher to extinguish
the fire.

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2 - Safety
DANGER
Heavy lifted load.
Risk of death or serious injury if incorrect lifting
equipment or incorrect lifting procedures are used.
– Stay clear of lifted loads.
– Use correct and applicable lifting equipment.
– Let only approved personnel do the lifting
procedures.
DANGER
Flinging of the tool.
Risk of death or serious injury due to loosely-
secured tools.
– Secure the tool tightly to the robot flange.
WARNING
Hot surfaces.
Risk of burns to skin.
– Do not touch the hot surfaces of the robot.
– Carry out maintenance activity only after the
robot components have cooled down to normal
temperature.
– Wear protective hand gloves.
WARNING
CAUTION
Slippery floor.
Risk of slipping and falling on floors with oily,
greasy residues or slippery production scrap.
– Wear slip-resistant safety shoes.
– Keep the work area clean and dry.

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2 - Safety
CAUTION
Heavy objects.
Kg
Risk of muscle strain or back injury.
– Use lifting devices or trolleys to transport heavy
objects.
– Use proper manual lifting techniques when
removing or replacing heavy objects.

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3 - Product description
3 Product description
The chapter describes the different components of the TAL BRABO robot.
3.1 Overview of the robot

The TAL BRABO robot comprises the following components:
1. Robotic arm
2. Teach pendant
3. Robot controller
3.1.1 Robotic arm

The robotic arm is an electro-mechanical mechanism that can move about the
following five axes (J1, J2, J3, J4 and J5):
J5
J4
3 -
+
J3
J2
1 2
- +
J1
Fig. 3-1 Robotic arm
1. Base plate
2. Mechanical limit indicator for J1-axis
3. Robot flange

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Axis Name Movement range Maximum speed

J1 Waist axis ±180° 110°/s
J2 Shoulder axis ±130° 110°/s
J3 Arm axis ±150° 110°/s
J4 Wrist tilting axis ±180° 150°/s
J5 Wrist rotational axis 360° 150°/s
The movement of the robotic arm about the different axes are achieved through
the respective stepper motor drives. Encoders monitor the actual position of
the different axes. Home position sensors monitor the home position of the
different axes.
A mechanical limit indicator (2) on the base plate (1) indicates the limit of the
robotic arm movement about the J1-axis. For safety of personnel and
equipment, software axis limits are defined to restrict the movement range of
the robotic arm about the different axes. The tool or end-effector is mounted
on the robot flange (3) to perform specific tasks such as cutting, welding,
gripping, etc.

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3.1.2 Teach pendant

The teach pendant consists of a touchscreen and two buttons. The teach
pendant is used to create/edit programs and operate the robot by means of
the teach pendant application installed on the teach pendant. Following is an
overview of the teach pendant:
5
3
4
7 6
Fig. 3-2 Teach pendant
No. Element Function

1 Power ON indicator Indicates that the teach pendant
is powered ON.
2 Emergency stop button Stops the robot immediately.
3 Mode selector switch Switches between Auto, Manual,
and Idle modes of operation.
4 Touchscreen Allows the user to set up and
operate the robot.
5 USB port (Rear) Allows the user to transfer data
between the teach pendant and a
USB drive.
6 Slave micro-USB slot (Rear) Allows the user to connect a
micro-USB device to the teach
pendant.
7 RJ45 port (Rear) Allows the user to connect the
teach pendant to a network for
TCP/IP communication with
other devices.
-- Stylus Allows the user to operate the
teach pendant.

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3.1.3 Robot controller

The robot controller controls the robotic arm. The robot controller consists of
a cabinet for housing the CPU, power supply, drive controllers, I/O and data
storage modules. The robot controller cabinet has connection points for power
supply, encoders, teach pendant, and optional spare points for connecting
other auxiliary components. The different components of the robot controller
are as follows:
Main components outside the robot controller
5
4 6
3 7
2 8
1 9
16 11 10
12 13
14 15
Fig. 3-3 Main components of the robot controller
No. Name Function

1 Robot controller Controls the robotic arm.
2 Main switch Turns ON or OFF the power
supply to the robot controller.
3 POWER ON lamp Glows when the power supply to
the robot controller is ON.
4 FAULT lamp Glows when there is a fault and
stops glowing after the fault is
reset.
5 CONTROL ON button Turns ON the robot controller.
Glows to indicate that the
controller is ON.
6 RESET button Resets the robot controller after a
fault.
7 Emergency stop button Stops the robotic arm
immediately, when pressed.
8 Spare communication port 1 --
9 Spare communication port 2 --
10 Ethernet (RJ45) port Port for connecting a computer for
troubleshooting and analysis.

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No. Name Function

11 230V utility socket Power socket for connecting
auxiliary equipment or external
devices.
12 Power socket (X1) Socket for connecting the power
cable from the robot controller to
the robotic arm.
13 Encoder socket (X2) Socket for connecting the
encoder cable from the robot
controller to the robotic arm.
14 Power supply connection Supplies power to the robot
controller.
15 Earthing screw Point for connecting the earthing
wire.
16 Teach pendant socket (X3) Socket for connecting the teach
pendant cable to the robot
controller.
Main components inside the robot controller
3 1
2
8
7
4 5
Fig. 3-4 Main components inside the robot controller

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No. Name Function

1 Central Processing Unit (CPU) Controls and co-ordinates the
movements of the robotic arm,
and communicates with I/O
devices connected to the CPU.
2 Drive controllers (Axes 1, 2, and Controls the stepper drives for
3) axes J1, J2, and J3.
3 Drive controllers (Axes 5 and 6) Controls the stepper drives for
axes J4 and J5.
4 SMPS (Switched-Mode Power Regulates the power supply from
Supply) the Mains to power the stepper
drives and various components of
the robot controller.
5 MCB (Miniature Circuit Breakers) Cuts the power supply to the
different components of the robot
controller to prevent damage to
the electrical circuits in case of
power surges or short circuits.
6 Temperature cut-out unit Turns OFF the power supply to
the robot controller when the
temperature inside the robot
controller exceeds a set value.
7 Cut-out temperature setting Sets the cut-out value for the
switch temperature inside the robot
controller.
8 Inlet fan Blows air into the robot controller
to cool the robot controller.
9 Exhaust fan Evacuates the hot air from the
robot controller to cool the robot
controller.

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3.2 Central Processing Unit (CPU)

The CPU controls and co-ordinates the movements of the robotic arm, and
communicates with I/O devices connected to the CPU. Following is an
overview of the CPU:
9
10
1 5
2
6
3 7
Fig. 3-5 CPU
No. Name Function

1 Ethernet port To connect a computer to the CPU
through an Ethernet cable for
communication with the CPU and
programming of the CPU.
2 Serial connection port To connect a computer to the CPU
through an RS 232 or RS 485
cable for communication and
data transmission.
3 Flexible axis port To connect additional encoders to
the CPU.
4 EtherCAT port To connect the different drives to
the CPU through an EtherCAT
connector.
5 Backlit display Displays the status (ON or OFF)
of the different I/O devices
connected to the onboard I/O
ports. Also displays the errors in
the drives, axes, I/O devices and
connections.
6 Power ON LED Glows when the CPU is powered
ON.
7 Enable status LED Glows when the CPU is enabled.
8 I/O channels To connect 8 inputs (Input
channels 0 to 7) and 8 inputs/
outputs (Bi-directional I/O
channels 8 to 15) to the CPU.

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No. Name Function

9 CAN Bus port To connect an additional CAN 16
I/O module for connecting
additional I/O devices to the CPU.
10 SD card slot To connect an SD card to the CPU
for transferring data between the
CPU and the SD card.
3.2.1 Backlit display on the CPU

The backlit display on the CPU shows the following information:
1
2
3
4
Fig. 3-6 Backlit display on the CPU
No. Name Function

1 IP address, Run / Error codes Displays the IP address of the
network connection, run time
codes and error codes.
2 Communication active indicator Glows when the communication
between the CPU and connected
modules is active.
3 EtherCAT connection status Blinks when the CPU is detecting
indicator an EtherCAT connection. Glows
continuously when the EtherCAT
connection is steady.
4 Error indicator Glows when the CPU detects an
error.
5 I/O channel status Displays the status (ON or OFF)
of the different I/O channels (Input
channels 0 to 7 and bi-directional
I/O channels 8 to 15).

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3.2.2 I/O channels on the CPU

The CPU has eight 24 V input channels (0 to 7) or connecting input devices
and eight bi-directional I/O channels (8 to 15) for connecting input or output
devices.
I0 I/O 8
I1 I/O 9
I2 I/O 10
I3 I/O 11
1 2
I4 I/O 12
I5 I/O 13
I6 I/O 14
I7 I/O 15
Fig. 3-7 I/O channels on the CPU
1. Input channels
2. Bi-directional I/O channels

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3.3 CAN 16 I/O module

To expand the number of I/O channels, a CAN 16 I/O module with 16 bi-
directional I/O channels can be connected to the CPU through a CAN Bus
connector. Upto 32 CAN 16 modules can be connected to the CPU to increase
the number of external bi-directional I/O channels to 512. The CAN 16 modules
are mounted on the DIN rail inside the robot controller and connected to the
CPU through the CAN bus connectors.
Fig. 3-8 CAN 16 I/O module
1. Bi-directional I/O channels

2. CAN Bus port
3.4 Removable storage

An SD card (FAT 32 format and maximum 1 GB storage capacity) can be used
in the SD card slot of the CPU for storing or transferring programs and data
to and from the CPU.

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3.5 Technical data

Parameter Value
Robot make TAL BRABO
Robot model TR10-5
Construction Articulated arm
Installation Floor and ceiling mounted
Ambient temperature of the robot 0 °C - 45 °C

workspace
Relative humidity of the robot workspace < 90%
Recommended area of fencing 2 m x 2 m = 4 m2
Recommended height of fencing 1.8 m
Number of axes 5
Axis movement range J1-axis: ±180°

J2-axis: ±130°
J3-axis: ±150°
J4-axis: ±180°
J5-axis: 360°
Maximum speed J1-axis: 110°/s
J2-axis: 110°/s
J3-axis: 110°/s
J4-axis: 150°/s
J5-axis: 150°/s
Maximum payload 10 Kg
Maximum reach (horizontal) 750 mm
Weight of robotic arm 95 Kg
Position repeatability (accuracy) ±0.2 mm
Main power supply 230V AC, Single phase,

Regulated power supply
Full load current 15 Amps
Maximum power consumption 4.5 kW
Operating temperature 0 °C - 45 °C
Acoustic level <70 dB
Robot controller dimensions 660 X 600 X 350 mm

Robot controller weight 45 Kg
Spare digital I/O 3 Input, 4 Output (Bi-
directional)
Communication protocol Ethernet, EtherCAT

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3.6 Recommended tightening torque for screws

Hexagonal socket Recommended tightening torque (Nm)
head cap screw Cast iron / Steel Aluminium
12.9 class
M3 1.90 0.69
M4 3.57 2
M5 8.56 4
M6 14.7 6.8
M8 35.5 17
M10 71.5 33.9
M12 122 61
3.7 Location of the name plate
Fig. 3-9 Location of the name plate
1. Name plate

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3.8 Payload and centre of gravity of the end-effector
Z D D Y
X
Fig. 3-10 Allowable position of the centre of gravity
The allowable position of the centre of gravity of the end-effector depends on

the payload. The allowable distance of the centre of gravity from the robot
flange depending on the payload is as given in the table below:
Payload (Kg) Allowable distance (D) of the

Centre of gravity from robot flange
along x, y and z axes (mm)
10 50
9 80
8 100
7 120
6 140
5 160
4 180
3 or less 210

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3.9 Centre of gravity of the robot during lifting

The centre of gravity of the robot is located at the point C.G. (80, -15, -250)
from the axis of the eye bolt.
X Z
C.G. (X= 80, Y= -15, Z= -250)
Fig. 3-11 Centre of Gravity (C.G.)of the robot during lifting (all dimensions in mm)

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4 - Transport and installation
4 Transport and installation

This chapter gives you information about the general precautions and correct
procedures to follow when the robot is transported into and installed at your
installation site.
4.1 Transport notes

The robotic arm and the robot controller are safely packed in separate wooden
crates for surface transport, sea transport, or air freight. The robotic arm and
the robot controller are supplied in assembled condition. Additional or optional
equipment are supplied in separate crates or pallets.
NOTICE
Obey all the applicable mandatory safety and accident prevention
rules during transport.
4.2 Contents of the package

The robot and the controller are delivered in two separate boxes with the
following contents:
One box contains the following:

▪ Robotic arm
▪ Teach pendant
▪ Teach pendant cable
▪ Power cable
▪ Encoder cable
▪ Fasteners for securing the robotic arm
The other box contains the following:

▪ Robot controller with its power connection cable
▪ Earthing cable
WARNING
Damage due to interchange of robot components.
Risk of personal injury or material damage due to
improper functioning.
– Do not interchange the robotic arm, the robot
controller, or the teach pendant of a pre-
configured set with similar components of
another set.

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4.3 Unpacking and inspection

It is recommended to get the wooden crates containing the robotic arm and
controller under the roof of the installation site and near its assigned position
before unpacking.
DANGER
Heavy lifted load.
procedures.
NOTICE
If the robotic arm or the robot controller is damaged on arrival, inform
TAL and the transport carrier immediately. If necessary, consult an
independent expert immediately. Take necessary photographs of the
damaged parts and send it to TAL as a first hand information.
Unpacking the box containing the robotic arm

The robotic arm is secured to the base pallet by using two bolts and wrapped
with bubble sheet. The procedure for unpacking the robotic arm is as follows:
1. Loosen and remove the screws that secure the top wooden cover to the
base pallet.
2. Remove the top cover of the wooden box along with the side walls and
keep it aside.
Fig. 4-1 Unpacking the robotic arm
3. Remove the packing materials.

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4. Remove the cables and fasteners and keep them at a safe place.
5. Loosen and remove the two bolts that secure the robotic arm to the base
pallet.
6. Visually examine the robotic arm for any damage.
Unpacking the box containing the robot controller

The procedure for unpacking the robot controller is as follows:
1. Loosen and remove the screws that secure the top wooden cover to the
base pallet.
2. Remove the top cover of the wooden box along with the side walls and
keep it aside.
Fig. 4-2 Unpacking the robot controller
3. Remove the strap that secures the robot controller to the base pallet.
4. Remove the packing materials.
5. Visually examine the robot controller for any damage.
After the boxes are unpacked, check whether all the components are received
as per the order. Keep the packing boxes in a safe place for later usage.
Dispose off the packing materials in accordance with the legal and
environmental regulations in force.

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4.4 Lifting the robotic arm

The procedure for lifting the robotic arm is as follows:
Prerequisites:
▪ If the robotic arm is just unpacked, make sure that you have removed the
securing bolts of the robotic arm to the base pallet.
▪ The location of the robotic arm’s centre of gravity is known.
Tools required:
▪ A crane or other hoisting equipment with a hook. The lifting capacity of the
hoisting equipment must be at least 100 kg.
▪ Lifting ropes or cables.
Procedure:
1. Attach the hook of the crane or hoisting equipment to the eyebolt on the
robotic arm.
Make sure that the position of axes are as shown in the following
figure so that the lifting hook is positioned exactly over the centre
of gravity of the robotic arm.
Fig. 4-3 Lifting the robotic arm

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DANGER
Heavy lifted load.
– Use correct and applicable lifting
equipment.
procedures.
2. Lift the robotic arm off the base pallet.
NOTICE
Take care of the centre of gravity while lifting the robotic arm.
3. Move the robotic arm to the required position and lower it.
4. Remove the hook of the crane or hoisting equipment from the eyebolt on
the robotic arm.

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4.5 Lifting the robot controller

The procedure for lifting the robot controller is as follows:
Prerequisites:
▪ The location of the robot controller’s centre of gravity is known.
Tools required:
▪ A crane or other hoisting equipment with a hook.The lifting capacity of the

hoisting equipment must be at least 100 kg.
▪ Lifting ropes or cables with hooks.
Procedure:
1. Attach the hooks on the lifting cable to the eyebolts on either side of the
robot controller.
Fig. 4-4 Lifting the robot controller
DANGER
Heavy lifted load.
equipment.
procedures.

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2. Lift the robot controller off the base pallet.
NOTICE
The robot controller must be transported and installed in an upright
position. Avoid excessive vibration or impact during transporting.
Excessive vibration or impact may damage the components inside the
robot controller.
3. Move the robot controller to the required position and lower it.
4. Remove the hooks of the crane or hoisting equipment from the eyebolts
on the robot controller.
4.6 Installation notes

Prepare the place of installation and foundations according to the foundation
plans supplied by TAL. The robot must be installed on a level floor with
sufficient load bearing capacity.
NOTICE
TAL disclaims all liabilities for any damage to the robot caused by
incorrect lifting procedures. Use only correct lifting equipment and let
only approved personnel do these tasks.
Obey all the precautions given in the following sections before installing the
robot and its components.
▪ Do not route the input/output wires and cables together with the power or
high voltage cables. The product might malfunction due to interference of
noise and surge voltage from power and high voltage cables to the signal
line. Route the wires of the product separately from power or high voltage
cables.
▪ Switch ON the robot only after all connections are done and proper earthing
is done.
▪ Take care that cables and wires, especially of tools and attachments, are
not entrapped during the robotic arm movements. Operate with all wires
and cables secured.
▪ Avoid twisting, folding, or applying excess force on the cables. Avoid
bending cables at sharp angles where they enter the product.

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4.7 Installation site and area

Before installing the robotic arm and the robot controller, confirm that the
installation site is in conformity with the laws and regulations of the country
where the robot is installed.
In an inappropriate environment, the robot will not operate to its full capacity
or performance, components may not last long, and unexpected failure may
result.
▪ Refer to the installation plan given by TAL for the robot and prepare the
installation area. Enough place must be available for functioning,
operation, and maintenance of the robotic arm and the robot controller.
▪ Make sure that the installation site is large enough to permit safe
procedures during installation.
▪ Operate the robot only at a site where the ambient temperature is between
0 °C and 45 °C.
▪ Operate the robot only at a site where the humidity is below 90%.
▪ Do not install the robotic arm or robot controller at a site that is exposed
to excessive vibration or impact.
▪ Do not install in areas with severe electrical or magnetic fields.
▪ Keep the installation area free from dust or oil mist.
4.8 Recommended tightening torque for screws

Hexagonal socket Recommended tightening torque (Nm)
head cap screw Cast iron / Steel Aluminium
12.9 class
M3 1.90 0.69
M4 3.57 2
M5 8.56 4
M6 14.7 6.8
M8 35.5 17
M10 71.5 33.9
M12 122 61

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4.9 Mounting the robot

Mount the robot on a strong, sturdy, and vibration-free surface that can
withstand the weight of the robot and the torque produced by the base joint.
Mounting the robotic arm on a non-sturdy platform causes the robot to shiver
during high speed and high payload manoeuvres thereby reducing the
accuracy and repeatability.
If the robotic arm is mounted on the ceiling, make sure that the ceiling is strong
enough to withstand the forces produced by the robotic arm. If the robotic arm
is mounted on a ceiling that has insufficient strength and rigidity, the robotic
arm might fall and cause serious injury to personnel or severe damage to the
robot system.
The robotic arm may be directly grouted to the floor or mounted on a platform
that is fixed on the floor. If the robotic arm is grouted to the ground, we suggest
to do a chemical grouting of the robotic arm base. Use 150 mm long Allen
screws for grouting.
The procedure for mounting the robotic arm on a platform is as follows:
Prerequisites:
▪ If the robotic arm is mounted on a platform, the platform must be erected

on a sturdy floor, duly levelled, and with holes as mentioned in the following
drawing:
45
380 ±0.2 PCD
12.5 (7 NOS)
THROUGH
Fig. 4-5 Mounting diagram - Robotic arm base (All dimensions in mm)
Tools required:
▪ A crane or other hoisting equipment with a hook.

▪ Lifting ropes or cables.
▪ Allen key set.

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Procedure:
1. Attach the hook of the crane or hoisting equipment to the eyebolt on the
robotic arm.
DANGER
Heavy lifted load.
equipment.
procedures.
2. Lift the robotic arm and bring it to a position above the platform.
NOTICE
Take care of the centre of gravity while lifting the robotic arm.
Make sure that the unit is kept balanced while it is being lifted by a
lifting device, and that no components or electrical leads are damaged.
3. Carefully position the robotic arm on the platform so that the seven holes
at the base of the robot align with the holes on the mounting platform.
NOTICE
Level the The robotic arm precisely on the platform. Poor setting may
lead to issues in accuracy, repeatability, and increased vibration of the
robotic arm.

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4. Use the seven M12 Allen screws (1) and washers to fasten the robotic arm
base (2) to the mounting platform. Make sure to tighten the Allen screws
in a star pattern and to the correct tightening torque.
See section “Recommended tightening torque for screws” in this chapter
for information about the recommended tightening torques of different
screws.
Fig. 4-6 Mounting the robotic arm base (representative image)
5. Remove the lifting cables from the robotic arm.

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4.10 Connecting the robotic arm and the robot controller

The robotic arm and the robot controller are connected using the following
cables and wires:
X3
X1 X2
4 3
5
X1 X2
2
1
Fig. 4-7 Connections to the robot
1. Power cable connecting the robotic arm and the robot controller.
2. Encoder cable connecting the robotic arm and the robot controller.
3. Teach pendant cable connecting the robot controller to the teach pendant.
4. Power cable connecting the robot controller to the main power source.
5. Earthing wire connecting the robotic arm and the robot controller.
Make sure the main power switch on the robot controller is turned OFF before
the connections are made. Connecting or disconnecting the cables while the
main power switch is ON might cause surges within the robot and damage
delicate components.
Connection to the power supply must be carried out by an authorised, qualified

electrician, following the relevant local regulations.
The instruction given in this section is only for guidance. Refer to the electrical
wiring diagram supplied along with the robot before connecting the electrical
and signal cables.
NOTICE
The robotic arm and the robot controller are configured as a set before
delivery. If you purchase two or more robot systems, take care not to
interchange the components of one set with similar components of
another set.

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4.10.1 Connecting the power cable

Power is connected to the robotic arm from the robot controller as follows:
Prerequisites:
▪ The robot controller is not connected to a power source.

▪ Power cable (1) of length 6 meters with 37-pin round-type connectors is
available (supplied along with the robot). The power cable is identified by
the label X1. The cable can also be identified by the alignment of pins or
holes with respect to the slot (2) on the connector. The pins or holes (3)
are aligned straight with respect to the slot.
3
1
Fig. 4-8 Power cable and connectors
Tools required:
▪ No tools are required.

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Procedure:
1. Insert the male end of the 37-pin connector to the socket labelled X1 on
the left side of the robot controller (4). Take care to align the groove on
the male connector end to the notch on the robot controller socket.
X3
X1 X2
4
5
X1 X2
Fig. 4-9 Power cable (X1) connections
2. Insert the female end of the 37-pin connector to the socket labelled X1 at
the rear side of the robotic arm (5). Take care to align the groove on the
female connector to the notch on the robotic arm socket.
3. Tighten the threaded cover of the connectors.
NOTICE
Make sure that the connections at both the ends of the cable are tight.
If the connections are loose, the robot might not function correctly.

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4.10.2 Connecting the encoder cable

Encoder connection between the robotic arm and the robot controller is done
as follows:
Prerequisites:

▪ Encoder cable of length 6 meters with 37-pin round-type connectors is
available (supplied along with the robot). The encoder cable is identified
by the label X2. The cable can also be identified by the alignment of pins
or holes with respect to the slot (2) on the connector. The pins or holes
(3) are aligned at an angle with respect to the slots.
Fig. 4-10 Encoder cable and connectors
Tools required:

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Procedure:
X3
X1 X2
4
5
X1 X2
Fig. 4-11 Encoder cable (X2) connections
2. Insert the female end of the 37-pin connector to the socket labelled X2 at
the rear side of the robotic arm (5). Take care to align the groove on the
female connector to the notch on the robotic arm socket.
3. Tighten the threaded cover of the connectors.
NOTICE
Make sure that the connections at both the ends of the cable are tight.
If the connections are loose, the robot might not function correctly.

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4.10.3 Connecting the teach pendant

The teach pendant is connected to the robot controller as follows:
Prerequisites:

▪ Teach pendant and the connected cable of length 6 meters with a 15-pin
round-type connector is available. The teach pendant cable is identified
by the label X3.
Fig. 4-12 Teach pendant cable
Tools required:
Procedure:
X3
1
X1 X2
Fig. 4-13 Teach pendant cable connections

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2. Tighten the threaded cover of the connector.
NOTICE
Make sure that the connection is tight. If the connections are loose,
the robot might not function correctly.
4.10.4 Connecting the earthing wire

The robotic arm and the robot controller must be grounded correctly (Protective
Earth) to prevent the risk of electrical shock and the occurrence of interference.
The grounding conductor must have at least the current rating of the highest
current in the system. The earthing wire is connected as follows:
Prerequisites:

▪ The earthing wire (supplied with the robot) is available.
Tools required:
▪ Spanner
Procedure:
1. Fix the earthing cable (1) on the earthing screw (2) on the left side of the
robot controller.
2. Tighten the nut (3) to the correct tightening torque.

screws.
4 23
X3 1
X1 X2
X1 X2
Fig. 4-14 Earth wire connections

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3. Fix the earthing cable on the earthing screw (4) at the rear side of the robotic
arm.
4. Tighten the screw (4) to the correct tightening torque.

screws.
WARNING
Improper earthing.
Risk of personal injury or damage to the robot due
to improper earthing. The robot may malfunction or
crash if the earthing is not proper.
The grounding conductor to the earth pit must be connected to the earthing
point on the robot controller. We recommend chemical earthing for the robot.
Observe the following guidelines for earthing:
▪ The earthing rod must be inserted at least 500 mm deep into the earth pit.
▪ The voltage between the earth pit conductor to the Neutral of the main
power supply must be less than 2V.
▪ The resistance of the wire from the earth pit conductor to a distance of 15
m around the earth pit must be less than 1 Ohm.
▪ Power supply variations must be within the specified limits (Single phase,
230 V, +/- 5%).
4.10.5 Connecting the robot controller to the main power source

The robot controller is connected to the main power source (Single phase, 230
V, 50-60 Hz) by a standard three-pin connector.Before connecting to the
mains, make sure that the main power switch on the robot controller is in OFF
position.
4.10.6 Checking the connections

After all the connections are done, check the following:
▪ Check that the power cable, encoder cable, teach pendant cable, and the
earthing wire are correctly connected.
▪ Check the voltage between Neutral and Earth connections with a
multimeter. The voltage must be less than 2V. The resistance must be less
than 1 Ohm.

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4.11 Mounting the end effector on the robot flange

Various end effectors or tools can be mounted on the robot flange (1). End
effectors must be connected to the robot flange using four M4 Allen screws.
Prepare the end effectors according to the mounting drawing in the following
figure:
20.3 ± 0 . 0 2
90
1
44 ±0.2 PCD
8.5 ±0.02
22.5
M 5( 4 N O S ) O N D I A 4 4 P C D
EQUISPACED AS SHOWN (THROUGH)
Fig. 4-15 Mounting diagram - Robot flange (All dimensions in mm)

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4.12 Repacking and storing the robot

If the robotic arm and the and the robot controller must be stored for transport
or kept idle for a long time, obey these precautions to give the equipment
sufficient protection:
DANGER
Heavy lifted load.
procedures.
1. Before dismantling the robot for storage, make sure to bring the robotic
arm to the following position.
Fig. 4-16 Packing position of the robotic arm
2. Switch OFF the main power switch on the robot controller.

3. Disconnect the robot controller from the main power source.

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4. Remove the Allen screws (1) that secure the robotic arm base (2) to the
platform.
Fig. 4-17 Screws on the robotic arm base (representative image)
5. Lift the robotic arm and the robot controller and move them to the base
pallets. Refer to the lifting sections mentioned earlier in this chapter for the
correct lifting procedures.
6. Secure the robotic arm to its base pallet and cover the robotic arm with
bubble sheets (3).
7. Pack all the cables and keep it along with the robotic arm package.

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8. Place the robot controller on the base pallet, cover the robot controller with
bubble sheets, and secure to the base pallet with straps (4).
3 4
Fig. 4-18 Packing the robotic arm and the robot controller
9. Use the top wooden covers to cover the robotic arm and the and the robot
controller. Use silica gel for protection from moisture.
10. Store the packages in a clean and dry place under the roof.
NOTICE
Obey all the applicable mandatory safety and accident prevention
rules during transport.

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5 - Operation
5 Operation
This chapter describes the operation of the TAL BRABO robot.
5.1 Safety precautions before switching ON the robot

Take the following precautions before switching ON the robot:
▪ Check the Main power supply.

▪ Check for voltage fluctuations. Use a UPS or voltage stabilizer in case of
excessive fluctuations.
▪ Check the electrical earthing. The potential difference between neutral and
earth must be less than 2 V.
▪ Check for proper functioning of all sensors on the CPU display in the robot
controller.
5.2 Switching ON the robot

The robot can be switched ON as follows:
WARNING
Prerequisites:
▪ The power cable is connected to the robot controller and the robotic arm.
▪ The encoder cable is connected to the robot controller and the robotic arm.
▪ The robot controller is connected to the Mains power supply.
▪ The teach pendant is connected to the robot controller.
▪ All emergency stop buttons are released.
▪ All faults are eliminated.
Procedure:
1. Turn ON the Mains power supply to the robot controller.

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5 - Operation
2. Turn the Main switch (1) on the robot controller (2) clockwise to ON position.
The POWER ON lamp (3) glows. The teach pendant application loads.
5
3
4
Fig. 5-1 Switching ON the robot
1. Main switch
2. Robot controller
3. POWER ON lamp
4. CONTROL ON button
5. RESET button
3. After 2 to 3 seconds, press the CONTROL ON button (4) on the robot

controller. The robot controller turns ON.
4. Press the RESET button (5) to energise the motors. After the motors are
energised, the motor brakes are released.

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5 - Operation
5.3 Overview of the teach pendant application

The teach pendant application is installed in the operating system of the teach
pendant. The teach pendant application helps to operate the robot by using
the various screens.
5.3.1 Screen structure

The teach pendant application has the following screen structure:
3
Fig. 5-2 Screen structure
Element Position Function

Navigation bar 1 Displays the tabs for navigating to the
different screens (See section
“Navigation bar” for more information)
Screen elements 2 Displays the different elements of the
selected screen.
Status bar 3 The status bar displays information
about the robot (See section “Status bar”
for more information).
5.3.2 Navigation bar
The navigation bar has several tabs for navigating to the different screens. The
navigation bar appears at the top of all screens. Following are the different tabs
on the navigation bar:
1 2 3 4 5 6 9
7 8
Fig. 5-3 Navigation bar

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5 - Operation
Tab Position Function

Program 1 Displays the Program screen.
On the Program screen, you can create
and edit robot programs, set and edit
parameters for the different program
instructions.
Installation 2 Displays the Installation screen.
On the Installation screen, you can
save a program, close a program, switch
user level or exit the teach pendant
application.
Jog 3 Displays the Jog screen.
On the Jog screen, you can jog the robot
to a required position and home the
robot.
I/O Status 4 Displays the I/O Status screen.
On the I/O status screen, you can
configure the different inputs and
outputs and switch them ON or OFF.
Variable 5 Displays the Variable screen.
On the Variable screen, you can define,
add and edit the variables required for
the robot program.
Shift 6 Displays the Shift screen.
On the Shift screen, you can set the U-
axis position, tool compensation and
define different user frames.
Home Offset 7 Displays the Home Offset screen.
On the Home Offset screen, you can
edit, enter and change the homing offset.
Error Log 8 Displays the list of errors in the robot and
the information about the errors.
Scroll arrows (left and 9 Scrolls to the left and right of the
right) navigation bar.

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5 - Operation
5.3.3 Status bar

The status bar displays information about the robot.
1 2 3 4
7 6 5
Fig. 5-4 Status bar
The status bar displays the following information:
Field Position Status

Current operating 1 ▪ Idle: The robot is idle.
mode ▪ Manual mode: The robot is in the
Manual mode.
▪ Auto mode: The robot is in the Auto
mode.
Homing status 2 ▪ Homing required: The robot is not
homed and must be homed.
▪ Homing done: The robot is homed.
Controller status 3 ▪ Controller Disabled: The robot
controller is disabled.
▪ Controller Enabled: The robot
controller is enabled.
Emergency stop 4 ▪ E-Stop Not Pressed: The
status emergency stop button is not
pressed.
▪ E-Stop Pressed: The emergency
stop button is pressed.
Program status 5 ▪ Program Not Running: The current
program is not running.
▪ Program Running: The current
program is running.
▪ Program Stopped: The current
program is stopped.
Active Co-ordinate 6 ▪ World: World co-ordinate system.
system ▪ Tool: Tool co-ordinate system
▪ User: User-defined co-ordinate
system
Current movement 7 ▪ Joint: Joint mode
mode ▪ Linear: Linear mode

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5 - Operation
5.4 User levels and rights

Two user levels are available in the teach pendant application - Operator and
Admin. The Admin login requires a password to login. Following are the rights
available for the two user levels:
Rights Operator Admin level

level
Jogging the robot Yes Yes
Homing the robot Yes Yes
Creating a new program No Yes
Opening a program Yes Yes
Editing a program No Yes
Saving a program No Yes
Running a program Yes Yes
Configuring I/O devices No Yes
Defining variables No Yes
Setting U-axis position No Yes
Setting tool compensation No Yes
Setting home offset No Yes
5.5 Logging in to the teach pendant application

After the robot is switched ON and the teach pendant application is loaded,
you can login with the Admin login or the Operator login (See section “User
levels and rights” for more information about user levels and rights).
Procedure:
For Admin 1. On the Login screen, click the Admin Login icon. A password box
login appears.
Fig. 5-5 Login screen

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5 - Operation
2. Click the password box. A keypad appears.
Fig. 5-6 Logging in to the Admin level
3. Enter the password for the Admin Login and click the Login key. The Main
window appears. You are now logged in to the Admin level.
Fig. 5-7 Main window
For Operator 4. On the Login screen, click the Operator Login icon. The Main window
login appears. You are now logged in to the Operator level. No password is
required for the Operator Login.

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5 - Operation
5.6 Operating modes

The robot has three modes - Manual, Auto and Idle modes.
Manual mode The Manual mode is used to perform operations such as jogging the robot,
creating a program or editing a program. In the Manual mode, the speed of
the robot is limited to 100 mm/s (Linear mode) and 15 degrees/s (Joint mode).
Auto mode The Auto mode is used to test or run a program. The maximum speed of the
robot in the Auto mode is 1000 mm/s (Linear mode) and 110 degrees/s (Joint
mode).
Idle mode The Idle mode is used to stop a program.
The current operating mode of the robot is displayed on the status bar of the
Teach pendant application (See section “Status bar” for details).
5.6.1 Switching from Manual to Auto mode

Prerequisites:
▪ All necessary preparations (arrangement of the tool to the robot flange)

are done to the robot and the robot workspace.
▪ No obstacles are present in the robot workspace.
▪ No personnel are present in the robot workspace.
▪ The robot is homed (See section “Homing the robot” for the detailed
procedure).
▪ The required program is opened from the Main window (See section
“Opening a saved program” for more information).
WARNING

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5 - Operation
Procedure:
1. Turn the mode selector switch (1) on the teach pendant clockwise to Auto
position (2). The robot is now in the Auto mode.
4
3
2
Fig. 5-8 Mode selector switch on the teach pendant
1. Mode selector switch

2. Auto position
3. Idle position
4. Manual position
5.6.2 Switching from Auto to Manual mode

Procedure:
1. Turn the mode selector switch (1) on the teach pendant counterclockwise
to Manual position (4). The robot is now in the Manual mode.
5.6.3 Switching to Idle mode

Procedure:
1. Turn the mode selector switch (1) on the teach pendant to Idle position
(3). The robot is now in the Idle mode.

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5 - Operation
5.7 Homing the robot

The robot must be homed whenever you:
▪ Switch ON the robot

▪ Restart the robot after an emergency stop
During homing, all robot axes move to their preset home positions. The home
positions of the different axes are monitored by the respective reference
sensors. An offset can also be defined to the home position of the robot (See
section “Setting the home offset”). Because all the robot joints have limited
range of movement, it is necessary to move the robot to a pre-homing position
to assist the homing process. The robot can be homed as follows:
Prerequisites:
▪ You are logged in to the teach pendant application (See section “Logging
in to the teach pendant application” for the detailed procedure).
▪ The robot is in the Manual mode (See section “Operating modes” for more
information).
WARNING

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5 - Operation
Procedure:
Pre-homing 1. On the navigation bar, click the Jog tab. The Jog screen appears.
the robot
Fig. 5-9 Jog screen
2. On the Jog screen, select Joint mode.
3. Jog the joint J1 (1) till the joint J1 is parallel to the connector plate (2) on
the robot base plate (3) as seen in the illustration below. (See section
“Jogging the robot” for more information about jogging the robot).
Make sure that the joint J1 is near the reference sensor (4).
4
2
3
Fig. 5-10 Pre-homing the robot

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5 - Operation
1. Joint J1
2. Connector plate
3. Robot base plate
4. Reference sensor
5. Joint J2
6. Joint J3
7. Joint J4
4. Jog the joint J2 (5) till it is parallel to the joint J1.
5. Jog the joint J3 (6) till it is perpendicular to the joint J2.
6. Jog the joint J4 (7) till the tool flange faces downwards. The robot is now
at the pre-homing position.
Homing the 7. On the Jog screen, click the Home key. The robot starts the homing
robot process. All robot joints (axes) move to their home positions.
5.8 Robot program

A robot program is a set of instructions to make the robot perform a required
task. The robot program is created by using the Program screen of the teach
pendant application.
The robot program can be used to define a series of points in the robot
workspace. The robot program can also send I/O signals to other machines
and devices. The robot program can also be used to define instructions such
as if, else, and loop, based on variables and I/O signals.

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5 - Operation
5.9 Structure of a robot program

The name of the current robot program and the robot program structure are
displayed in the window on the left-hand side of the Program screen.
Fig. 5-11 Program screen
1. Robot program structure

2. Name of the robot program
The robot program has a tree structure consisting of several program

instructions:
Robot Program
Program instruction 1
Program sub-instruction
Program sub-instruction
Fig. 5-12 Robot program structure
Different program instructions (from a list of program instructions) can be

added to the robot program one below the other. It is also possible to nest a
program instruction under another program instruction. The parameters of the
program instruction can be edited in the Command page (See sections
“Creating a new program” and “Program instructions” for more information).

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5 - Operation
5.10 Creating a new program

You can create a new robot program as follows:
Prerequisites
▪ You are logged in to the teach pendant application with the Admin level.
information).
procedure).
▪ All necessary preparations (like arrangement of tool to the robot flange)
are done on the robot.
Procedure
1. On the Main window, click the NEW PROGRAM icon. The Program
screen appears.
The robot program structure (1) and the name (2) of the robot
program is displayed on the left of the Program screen.
For a new program, the default name is Untitled and the robot
program structure is empty.

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5 - Operation
Fig. 5-14 Program screen
1. Robot program structure

2. Name of the robot program
Adding program 2. On the Program screen, click the Structure tab. The Program Structure
instructions Editor page with a list of program instructions appears.
3. Click Robot Program on the robot program structure.
Fig. 5-15 Program Structure Editor page
4. Click the required program instructions from the list to add them to the robot
program structure.

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5 - Operation
Setting the 5. On the robot program structure, select the individual program instructions
parameters one by one and click the Command tab. The Command page shows the
parameters for the respective instruction.
Fig. 5-16 Command page for the IF instruction
6. On the Command page, set and save the parameters, conditions,

attributes and variables for the selected program instruction (See section
“Program instructions” for information about the different program
instructions and their command pages).
7. Save the project after every three instructions to avoid loss of the program
(See section “Saving a program” for more information).

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5 - Operation
5.11 Program instructions

Eight program instructions are available to create a program for the robot. On
the Program screen, click the Structure tab to see the list of available program
instructions.These program instructions can be added to the robot program
one by one. The structure of the program is displayed on the left of the Program
screen. Under the Command tab, you can set the parameters, conditions and
variables for the respective program instruction.
Fig. 5-17 List of available program instructions
The different program instructions with their respective parameters are

explained as follows:

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5 - Operation
5.11.1 MOVE
The MOVE instruction moves the robot to a set point.
Click the MOVE icon in the Program Structure Editor page to add the MOVE
instruction to the robot program. A POINT instruction is automatically nested
under the MOVE instruction. You may add additional POINT instructions under
the MOVE instruction.To edit the parameters of the MOVE instruction, select
the MOVE instruction in the robot program structure and click the Command
tab.
Fig. 5-18 Command page for the MOVE instruction
The parameters for the MOVE instruction are as follows:
Mode:
Selects the mode of robot movement (Linear, Joint or Arc).
Linear: The point(s) defined under the selected Move instruction will be set
to Linear mode. In the linear mode, a point is defined by the X, Y and Z co-
ordinates of the Tool Centre Point (TCP) of the robot. The movements of the
different robot joints are automatically interpolated till the TCP reaches this
point.
Joint: The point(s) defined under the selected Move instruction will be set to
Joint mode. In the joint mode, a point is defined by the positions of the
respective joints of the robot.
Arc: The point(s) defined under the selected Move instruction will be set to
Arc mode. This mode is used to move the robot along a curve.
Joint Speed (°/s):

Sets the speed of movement of the robot during the selected MOVE instruction.
Joint Acceleration (°/s2):

Sets the acceleration of the robot during its movement in the selected MOVE
instruction.

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5 - Operation
Frame:
Selects the frame (coordinate system) in which the points under the selected
MOVE instruction are defined. You can select from World, Tool and User
frames.
Only World frame is available for this robot.
▪ World frame: The World frame is a permanently fixed cartesian co-

ordinate system.
▪ Tool frame: The Tool frame is a cartesian co-ordinate system. By default,
the origin of the Tool frame (TCP) is located at the centre point of the robot
flange.
▪ User frame: The User frame is a co-ordinate system in which the origin
can be defined by the user.
Merger (%):
Sets the merger value (in percentage) for the robot movement during the
selected MOVE instruction. This can be set only when the Merge option is
activated. When the robot moves from one point to another, there can be jerks
and vibrations. The Merger option makes the robot trace a smooth curve (fillet)
as it changes its axis of movement. This helps to dampen the jerks and
vibrations. Higher the value of the Merger (%) parameter, higher is the radius
of the fillet (See section “Using the Merge option and teaching a fillet profile”
for more information).
Merge:
Activates the Merge option for the robot movement during the selected MOVE
instruction. When the Merge option is activated, the robot will not stop at a point
before moving to the next point (defined under the selected MOVE instruction).
The robot will keep moving to the next point (See section “Using the Merge
option and teaching a fillet profile” for more information).
Stop at this point:

Activates the Stop at this point option for the robot movement during the
selected MOVE instruction. When this option is activated, the robot will stop
at every point before moving to the next point (defined under the selected
MOVE instruction).
Save:
Saves the set parameters on the Command page of the selected MOVE
instruction.

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5 - Operation
5.11.2 POINT
The POINT instruction is a sub-instruction of the MOVE instruction. The POINT
instruction defines the robot position for the selected point under the MOVE
instruction.
A POINT instruction is automatically nested under a MOVE instruction when
you add a MOVE instruction to the robot program. To add additional points
under the MOVE instruction, click the POINT icon in the Program Structure
Editor page. To edit the parameters of the POINT instruction, select the POINT
instruction in the robot program and click the Command tab.
Fig. 5-19 Command page for the POINT instruction
The parameters for the POINT instruction are as follows:
Rename:
Changes the point to the required name for easy identification of the point.
Read Current Position:

Reads the current position of the robot and shows the position in the Current
Position window.
Current Position (X, Y, Z, U, V):

Displays the current position of the robot.

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5 - Operation
Set This Point:

Displays the Jog screen for teaching a point. Only the mode (Linear or Joint)
selected in the Command page of the MOVE instruction is active.
Fig. 5-20 Set this point
Jog the robot to the required position (See section “Jogging the robot” for the
detailed procedure) and click the SAVE key on the Jog screen. The taught
positions of the respective axes are displayed in the Teach Position window
in the Command page of the POINT instruction.
Teach Position (X, Y, Z, U, V):

Displays the taught positions of the respective robot axes. These are the
positions of the different robot axes defined for the selected point.
Move Robot Here:

Moves the robot to the teach position. All robot axes move to the respective
positions shown in the Teach Position Window. After the robot reaches the
teach position, the values in the Current Position and Teach Position
windows are equal. This key is used to bring the robot back to the teach position
after the robot is jogged for testing or checking.
Edit Point:
To edit and save the already taught points.

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5 - Operation
5.11.3 WAIT
The WAIT instruction makes the robot wait till a set condition is satisfied, before
proceeding to the next step in the program.
Click the WAIT icon in the Program Structure Editor page to add the WAIT
instruction to the robot program.
Fig. 5-21 Command page for the WAIT instruction
Select the WAIT instruction in the robot program and click the Command tab.
The Command page for the WAIT instruction appears. On the Command
page for the WAIT instruction, select one from the following available options:
Wait (msec):
The robot waits for the set time duration (in milliseconds), before proceeding
to the next step in the program.
Wait for Digital Input (Digital Input XX) (High/Low):

The robot waits for the selected digital input to be high or low, before proceeding
to the next step in the program. Select the required digital input and the status
(High or Low) on the respective menus.
Wait for (Entity) (Operator) (value)mA:

The robot waits for the selected entity to reach, fall below, or rise above a set
value, before proceeding to the next step in the program. Select the required
entity and operator, and enter the value on the respective menus.
You can choose one of the following entities:
▪ Analog inputs (Channels 0 and 1)

▪ Analog outputs (Channels 0 to 3)
▪ Digital inputs (Channels 0 to 95)
▪ Digital outputs (Channels 8 to 95)
Channels 8 to 95 are bi-directional ports. These can be configured

either as digital input or digital output ports.

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5 - Operation
The available operators are:
▪ Greater than (>)

▪ Less than (<)
▪ Equal to (=)
For example, If you set the condition as “Wait for Analog Input 0 < 9mA”, the
robot waits for the analog input 0 to be less than 9mA, before proceeding to
the next step in the program.
Wait for (set condition):

The robot waits for the set condition to be satisfied, before proceeding to the
next step in the program. Click the text box. A window for entering the required
condition appears.
The window has a text box in which you can enter a condition by using input,
outputs, operators, variables, and numbers.
2 3
7
8
4
5
10 9
Fig. 5-22 Window for entering the required condition
1. Menu for adding an input

2. Menu for adding an output
3. Menu for adding an operator
4. Menu for adding a variable
5. Text box for the condition
6. Condition
7. Remove key
8. Numeric KeyPad
9. OK key
10. Close key
Adding an input into the text box (1):
▪ On the <Input> menu, select the required input (Channels 0 to 95) and
then click the Add key (below the <Input> menu) to add the input into the
text box.

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5 - Operation
Adding an output into the text box (2):
▪ On the <Output> menu, select the required output (Channels 8 to 95), and
then click the Add key (below the <Output> menu) to add the output into
the text box.
Adding an operator into the text box (3):
▪ On the <Operator> menu, select the required operator, and then click the
Add key (below the <Operator> menu) to add the operator into the text
box.
Adding a variable into the text box (4):
▪ On the <VR> menu, select the required variable, and then click the Add
key (below the <VR> menu) to add the variable into the text box. Fifty
system variables (VR 900 to VR950) are available. You can also select
from the additional user defined variables.
Adding a number into the text box (5):
▪ Click the Numeric KeyPad key. A numeric key pad appears. Use the
numeric keypad to enter a number into the text box.
Removing a line from the text box (7):
▪ Select a line in the text box and click the Remove key to remove the line
from the text box.
Saving the entered condition (9):
▪ Click the OK key to save the entered condition. The Command screen
appears.
Going back to the Command screen without saving a condition (10):
▪ Click the Close key. The Command screen appears.
Save:
Saves the set parameters on the Command page of the selected WAIT
instruction.

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5 - Operation
5.11.4 SET
The SET instruction makes the robot perform an action at the selected point
in the program.
Click the SET icon in the Program Structure Editor page to add the SET
Fig. 5-23 Command page for the SET instruction
Select the SET instruction in the robot program and click the Command tab.
The Command page for the SET instruction appears. On the Command page
for the SET instruction, select one from the following available options:
Set Digital Output (Digital Output XX) (High/Low):

The robot sets the specified Digital output (channels 8 to 95) as High or Low,
at this point in the program. Select the required digital output and the status
(High or Low) on the respective menus.
Set Analog Output (Analog Output XX) (value)mA:

The robot sets the specified Analog output (channels 0 to 3) to the specified
value, at this point in the program. Select the required analog output and enter
the required value on the respective menus.
Set Variable (Variable) (operator) (value):

The robot sets the specified variable to the specified value, at this point in the
program. Select the required variable and operator, and enter the required
value on the respective menus.
For example, If you set the condition as “Set Variable VR(903) + 6", the robot
will increase the value of the variable VR(903) by 6.
Save:
Saves the set parameters on the Command page of the selected SET
instruction.

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5 - Operation
5.11.5 IF....ELSE
The IF instruction makes the robot perform an action if the specified condition
is satisfied. The optional ELSE instruction makes the robot perform an
alternate action if the specified condition is not satisfied.
Click the IF....ELSE icon in the Program Structure Editor page to add the
IF instruction to the robot program.
Select the IF instruction in the robot program and click the Command tab. The
Command page for the IF....ELSE instruction appears. On the Command
page for the IF instruction, click the text box. A window for entering the required
condition appears.

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2 3
7
8
4
5
10 9

6. Condition
7. Remove key
8. Numeric KeyPad
9. OK key
10. Close key
text box.
the text box.
box.

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5 - Operation
from the text box.
appears.
Add Else:
Adds an Else step to the robot program to make the robot perform an alternate
action, if the specified condition is not satisfied.
Save:
Saves the set condition on the Command page of the selected IF....ELSE
instruction.

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5 - Operation
5.11.6 LOOP
The LOOP instruction makes the robot repeat the nested instructions for a set
number of times or until a specified condition is satisfied.
Click the LOOP icon in the Program Structure Editor page to add the LOOP
Fig. 5-26 Command page for the LOOP instruction
Select the LOOP instruction in the robot program and click the Command tab.
The Command page for the LOOP instruction appears. On the Command
page for the LOOP instruction, select one from the following available options:
Loop Always:
The robot repeats the nested instructions continuously.
Loop for (Number of) Times:

The robot repeats the set of instructions for the predefined number of times
entered by the user.
Loop for (set condition) Function:

The robot repeats the nested instructions until the specified condition is
satisfied. Click the text box. A window for entering the required condition
appears.

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2 3
7
8
4
5
10 9

6. Condition
7. Remove key
8. Numeric KeyPad
9. OK key
10. Close key
text box.
the text box.
box.

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5 - Operation
from the text box.
appears.
Save:
Saves the set parameters on the Command page of the selected LOOP
instruction.
5.11.7 HALT
The HALT instruction is used to stop the program. The robot stops at this
instruction.

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5 - Operation
5.11.8 JUMP
The JUMP instruction makes the robot run a specified sub-instruction (Label).
Fig. 5-28 Command page for the JUMP instruction
To add a JUMP instruction to the robot program:
1. On the Program Structure Editor page, click the JUMP icon. A JUMP
instruction is added to the robot program structure.
2. Select the JUMP instruction in the robot program and click the Command
tab. The Command page for the JUMP instruction appears.
3. On the Command page for the JUMP instruction, click the Add Label key.
A new program label is added to the robot program structure.
You can also select an existing program label from the list. The
selected Label instruction is added to the robot program.
4. Click the Save key.
Renaming the 5. Select the Label instruction in the robot program. The Command page
label for the Label instruction appears.

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6. Click the Rename Label key to rename the Label.
Fig. 5-29 Command page for the LABEL instruction
7. Under the Label instruction in the robot program, select <Empty> and click
the Command tab. The Command page opens.
Fig. 5-30 Adding a structure under a Label instruction
8. On the Command page, click the Structure tab. The Program Structure
Editor page appears.

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9. Add the required program instructions from the list to the program label
(The procedure to add instructions to the program label is similar to that
of adding instructions to the robot program. See section “Creating a new
program” for the detailed procedure).
Fig. 5-31 Adding a structure under a Label instruction

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5.12 Program structure editor instructions

Seven Program structure editor instructions are available for editing the
structure of the program. On the Program screen, click the Edit Program tab
to see the list of available program structure editor instructions. Select the
required program instruction in the robot program and click the Program
structure editor instruction.
Fig. 5-32 List of Program structure editor instructions
The different program structure editor instructions are explained as follows:
MOVE UP:
Moves the selected program instruction up in the robot program structure.
MOVE DOWN:
Moves the selected program instruction down in the robot program structure.
COPY:
Copies the selected program instruction in the robot program structure. This
program instruction can be pasted at a selected location in the robot program.
CUT:
Cuts the selected program instruction from the robot program structure. This
program instruction can be pasted at a selected location in the robot program.
PASTE:
Pastes the copied or cut program instruction at the selected position in the robot
program structure.
DELETE:
Deletes the selected program instruction from the robot program structure.

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SUPPRESS:
Suppresses the selected program instruction in the robot program structure.
The suppressed program instruction(1) is highlighted in green colour. The
robot skips the suppressed step and proceed to the next program instruction
in the robot program. To unsuppress the program instruction, select the
suppressed instruction in the robot program structure, and then click
SUPPRESS.
Fig. 5-33 SUPPRESS instruction

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5.13 Saving a program

After creating or editing a program in the Program screen, it can be saved
as follows:
Prerequisites:
information).
▪ The robot program is created or edited in the Program screen.
Procedure:
Saving a new program 1. On the navigation bar, click the Installation tab. The Installation screen
appears.
Fig. 5-34 Installation screen
2. Click the Save Project key. The Save window appears.
3. Select the destination for saving the program.
4. Enter the name and select the file type of the program in the Name and
Type boxes.
5. Click the OK key on the Title bar of the Save window. The program is saved
at the set destination with the set name and file type.

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Saving an existing 1. On the navigation bar, click the Installation tab. The Installation screen
program as a new appears.
program
2. Click the Save As key. The Save As window appears.
3. Select the destination for saving the program. Use the keys on the title bar
of the Save As window for this purpose.
Type boxes.
5. Click the OK key on the Title bar of the Save As window. The program
is saved at the set destination with the set name and file type.

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5.14 Opening a saved program

You can open a saved robot program as follows:
Prerequisites
▪ You are logged in to the Teach pendant application with Admin or

Operator level.
Procedure
1. On the Main window, click the OPEN PROGRAM icon. The Open window
appears.
Fig. 5-37 Open window
2. Select the destination in which the required program is saved. Use the keys
on the title bar of the Open window for this purpose.

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3. Select the required program from the folder. You may also enter the name
and select the file type of the program in the Name and Type boxes to find
the program in the folder.
4. Click the OK key on the Title bar of the Open window. The Program screen
appears with the selected program.
5.15 Editing a program

You can edit a program as follows:
Prerequisites:
information).
▪ You are logged in to the Teach pendant application with the Admin level.
▪ The required program is open in the Program screen.
Procedure:
Adding new 1. On the Program screen, click the Structure tab. The Program Structure
instructions Editor page with a list of program instructions appears.
2. Click the required program instruction from the list to add them to the
program structure. The program structure with the added program
instructions is displayed as a tree diagram on the left of the Program
screen.

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Editing the 1. On the robot program structure, select the program instructions one by one
parameters and click the Command tab. The Command page for the selected
program instruction appears.
2. On the Command page, set the parameters, conditions, attributes and

variables for the selected program instruction (See section “Program
instructions” for information about the different program instructions and
their Command pages).
3. On the Command page, click the Save key to save the set parameters,
conditions, attributes and variables for the selected program instruction.
Editing the 1. On the Program screen, click the Edit Program tab. The Program
program structure Structure Editor page with a list of program structure editing instructions
appears.

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2. On the Program structure tree, select the required step and click the
required program structure editor instruction from the list to edit the
program structure. (See section “Program structure editor instructions” for
information on the program structure editor instructions).
5.16 Testing a program

After creating and saving a program, you can test it as follows:
Prerequisites:

procedure).
▪ The robot is in the Auto mode (See section “Operating modes” for more
information).
▪ The required program is saved.
Procedure:
1. On the Program screen, click Robot Program on the robot program

structure tree.
2. Click the Command tab. The Command page appears.
Fig. 5-41 Testing a program

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3. On the Command page, click the Step key. The robot will run one step
and stop.
Move the slider at the bottom-right of the screen to adjust the speed
of the robot.
4. Click the Next key to proceed to the next step.
5. Check if the program runs as required. If any changes are required, edit
the program (See section “Editing a program” for the detailed procedure).

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5.17 Running a program

A program can be run as follows:
Prerequisites:
▪ All necessary preparations (tool, work piece) are done to the robot and the
robot workspace.
procedure).
▪ The robot is in the Auto mode (See section “Operating modes” for more
information).
▪ The required program is saved.
Procedure:

structure tree.
2. Click the Command tab. The Command page appears.
Fig. 5-42 Running a program
3. On the Command page, click the RUN key. The robot runs the program.
4. Move the slider at the bottom-right of the screen to adjust the speed of the
robot.

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5.18 Pausing a program

You can pause a running program as follows:
Procedure:

structure tree.
2. On the Command page, click the PAUSE key. The program pauses.
Fig. 5-43 Pausing a program

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5.19 Resuming a program after a pause

After a pause, you can resume the program from the point it was paused. You
can resume a paused program as follows:
Procedure:

structure tree.
2. On the Command page, click the RESUME key. The program resumes.
Fig. 5-44 Command page

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5.20 Stopping a program

A running program can be stopped as follows:
Procedure:
1. On the Command page, click the STOP key. The program stops.
Fig. 5-45 Command page
You cannot resume a stopped program.

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5.21 Jogging the robot

The robot axes can be moved to different positions by jogging. The robot can
be jogged for homing, testing and teaching the different positions.
You cannot jog the robot when a program is running.
The robot can be jogged as follows:
Prerequisites:
▪ The robot is switched ON and the teach pendant application is loaded (See
section “Switching ON the robot” for more information).
information).
Procedure:
1. On the navigation bar, click the Jog tab. The Jog screen appears.
Make sure that the teach pendant connection status indicator at

the bottom right of the Jog screen is green. If red, check the
connection between the teach pendant and the robot controller.
Fig. 5-46 Jog screen
2. On the Jog screen, select Linear or Joint mode.

▪ Linear: In this mode, you can move tool centre point in straight lines
along the selected axes. The different joints of the robot will move in
combination to maintain the tool centre point in a straight line during its
movement along the different axes.

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▪ Joint: In this mode, you can independently jog the different joints (one,
at a time) by the required degree. The position of the tool centre point
cannot be directly predicted in this mode. The TCP is predicted based on
the resultant positions of each axis.
3. Move the slider at the bottom-left of the screen to adjust the jog speed.
The jog speed is specified as a percentage of the maximum

possible jog speed. The maximum possible jog speed is 100mm/s.
Linear mode 4. Under Linear, click the + or - keys next to the required axis (X, Y, Z, U,
V) to jog the Tool Centre Point (TCP) in a straight line along the respective
axis. For example, clicking the + or - keys next to the X axis jogs the Tool
Centre Point (TCP) in a straight line along the X axis. In the linear mode,
the movement of X, Y and Z axes are in mm.
Joint mode 5. Under Joint, click the + or - keys next to the required joint (J1, J2, J3, J4,
J5) to move the respective joint forward or backward.
For example, clicking the + or - keys next to J2 jogs the joint J2 forward
or backward. In the linear mode, the movement of joints are in degrees.

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5.22 Configuring inputs and outputs, I/O

Inputs and outputs can be configured as follows:
Prerequisites:
▪ The required input and output devices are connected to the robot
controller.
▪ You’re logged in to the teach pendant application with the Admin level (See
section “Logging in to the teach pendant application” for more information).
Procedure:
1. On the navigation bar, click the I/O Status tab. The I/O Config screen
appears.
Fig. 5-47 I/O Status screen
2. Click Edit.
3. Under ONBOARD, set the bi-directional channels (8 to 15) to either Digital

Input #, Robot Output #, or a PLC Output #. This will depend on the actual
hardware connected to the respective I/O channel.
4. Click the required Node key (Node 1 to Node 5). The page for setting the
bi-directional I/O channels of the selected Node appears on the right of
the I/O Config screen.
The nodes are the additional bi-directional I/O ports which are
connected to the control panel.

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5. Under Node #, set the bi-directional channels for the respective node to
either Digital Input #, Robot Output # or a PLC Output #. This will depend
on the actual hardware connected to the respective I/O channel of the
control panel.
▪ Node 1: Channels 16 to 31
6. Click Save.

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5.23 Turning ON and OFF the inputs and outputs

You can turn the inputs and outputs ON and OFF as follows:
Prerequisites:
▪ The inputs and outputs are configured (See section “Configuring inputs
and outputs, I/O” for the detailed procedure).
Procedure:
Onboard I/Os 1. Under the I/O Status tab, click the ONBOARD IOs tab. The ONBOARD
IOs screen appears.
Fig. 5-48 ONBOARD IOs screen
2. Under INPUTS, you can see the status (ON or OFF) of the different input
channels (0 to 7).
You cannot change the status of the onboard input channels (0 to 7).
3. Under BI-DIRECTIONAL, select the check box next to the required

onboard I/O channel (channels 8 to 15) to turn it ON. (Deselect the check
box to turn it OFF). The status of the I/O channel is displayed to the right.
Nodes 1. Click the NODE 1 tab. The list of configured I/O channels on Node 1
appears.
2. Under BI-DIRECTIONAL, select the check box next to the required I/O
channel to turn it ON. (Deselect the check box to turn it OFF). The status
of the I/O channel is displayed to the right.
3. Similarly, switch ON or OFF inputs and outputs on the other nodes.

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5.24 Defining the variables

You can define the different variables used in a program as follows:
Prerequisites:
▪ You’re logged in to the teach pendant application with the Admin level (See
Procedure:
1. On the navigation bar, click the Variable tab. The Variable screen with the
list of variables, their Attribute, Category and Value appears. Fifty one
system variables (VR 900 to 950) are available. You may edit these
variables for use in the program. You can also define new variables.
Fig. 5-49 Variable screen
Adding a new 1. On the Variable screen, click the Add key. A window appears.
variable
Fig. 5-50 Adding a new variable

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2. Enter the name of the variable in the Variable Name box.
3. Enter the initial value of the variable in the Variable Value box.
4. Select Read Only or Read Write to set the variable type. A Read Only
variable can only be read and cannot be overwritten. A Read Write variable
can be read as well as overwritten.
5. Click OK. The new variable appears in the list.
Editing a 1. On the Variable screen, select the required variable, and click the Edit
variable key. A window appears.
You cannot edit a system variable (VR900 to VR950).
Fig. 5-51 Adding/ Editing a variable
2. Enter the name of the variable in the Variable Name box.
3. Enter the initial value of the variable in the Variable Value box.
4. Select Read Only or Read Write to set the variable type. A Read Only
variable can only be read and cannot be overwritten. A Read Write variable
can be read as well as overwritten.
5. Click OK.
Deleting a 1. On the Variable screen, select the required variable and click the Delete
variable key. The selected variable is deleted from the list.
Click the Save key to save the changes made on the Variable
screen.

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5.25 Restarting the robot after a fault

In case of a fault, the robot stops. A fault message is displayed on the teach
pendant screen and the FAULT lamp (1) on the robot controller (2) glows. You
can restart the robot as follows:
Procedure:
1. Check the robotic arm and the robot controller to identify the fault.
2. Do the necessary steps to solve the fault.
3. Press the RESET button (3) on the robot controller (2). The FAULT lamp
(1) stops glowing.
1 3
Fig. 5-52 Restarting the robot
1. FAULT lamp
2. Robot controller
3. RESET button
4. Press the CONTROL ON button (4).

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5.26 Stopping the robot in an emergency

In an emergency, the robot can be stopped as follows:
Procedure:
1. Press the nearest emergency stop button (1). The robotic arm and robot
controller stops immediately. By default, emergency stop buttons are
installed at the following locations:
▪ On the robot controller (2)
▪ On the teach pendant (3)
Additional emergency stop buttons may be added by the integrator.

Refer to the instructions provided by the integrator.
Fig. 5-53 Emergency stop buttons
1. Emergency stop button

2. Robot controller
3. Teach pendant

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5.27 Restarting the robot after an emergency stop

After an emergency stop, you can restart the robot as follows:
Procedure:
1. Check the robotic arm and the robot controller to identify the fault.
2. Do the necessary steps to solve the fault.
3. Turn the emergency stop button (1) to release it. By default, emergency
stop buttons are installed at the following locations:
▪ On the robot controller (2)
▪ On the teach pendant (3)
Additional emergency stops may be added by the integrator. Refer

to the instructions provided by the integrator.
4. Press the CONTROL ON button (4), and then the RESET button (5) on
the robot controller.
4 5
1
Fig. 5-54 Restarting the robot
1. Emergency stop button

2. Robot controller
3. Teach pendant
5. RESET button
5. Home the robot (See section “Homing the robot” for the detailed
procedure).

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5.28 Closing the current program

You can close the current program as follows:
Prerequisites:
▪ The current program is stopped.
Procedure:
1. On the navigation bar, click the Installation tab. The Installation screen
appears.
2. Click the Close Project key. The current project closes and the Main
window appears.

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5.29 Deleting a program

You can delete a program as follows:
Prerequisites:
▪ No program is running.
Procedure:
1. Exit the teach pendant application. The Desktop page appears. (See
section “Exiting the teach pendant application” for the detailed
information).
Fig. 5-56 Desktop page
2. On the Desktop page, go to My Device>Program Files>Teach Pendant
3. Right click on the required program, and then select Delete. The selected
program is deleted.

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5.30 Managing errors

5.30.1 Viewing the error log
You can view the error log as follows:
Procedure:
1. On the navigation bar, click the Error Log tab. The error log appears. The
error log lists the various errors occurring in the machine over a period of
time along with the details.
1 2 3 4 5
Fig. 5-57 Error log
1. Axis number
2. Error type
3. Error time
4. Error code
5. Axis Following Error
2. Click the Refresh Error Log key to refresh the error log and see the more
recent list of errors.

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5.30.2 Downloading the error log

You can download the error log as follows:
Procedure:
1. On the navigation bar, click the Error Log tab. The error log appears.
2. Click the Download Error Log key. A window appears.
3. Select the destination for saving the file.
Type boxes.
5. Click OK. The error log file is downloaded to the selected destination with
the set name and file type.
You may copy the error log from this destination to a USB device.

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5.31 Setting the home offset

In some cases, the default home position of the robot may not be a good starting
position for running a program because of workspace constraints, other robots,
and obstacles. The home position of the robot can then be offset by a required
amount to ensure a good starting position for running a program.
J4
J3 -Z
3
+Z -U
+U
4
J2 2
-Y +Y
J1
+X
-X 1
Fig. 5-58 Home offset
1. Default home position of the J1-axis

The home position of the robot can be offset as follows:
Prerequisites:
▪ You are logged into the teach pendant application with the Admin level (See
section “Logging in to the teach pendant application” for the detailed
procedure).
WARNING
If the HOME position is modified, this affects all programs in which
it is used. Physical injuries or damage to property may result.

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Procedure:
1. On the navigation bar, click the Home Offset tab. The Home Offset screen
appears.
Fig. 5-59 Home Offset screen
2. On the Home Offset screen, click the Edit key.
3. Enter the required offsets (in degrees) for the home positions of the
respective axes (X, Y, Z, U and V). E.g. Entering an offset for X shifts the
first axis (J1) by the set degrees.
4. Click the Save key to save the entered offset values. The home positions
of the axes are now set to the new values. The axes stops at these
positions, the next time you home the robot.

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5.32 Setting the U-axis position

In some cases, it might be necessary to shift the position of the U-axis (J4-
axis) from its home position to suit special job requirements. When you shift
the U-axis position, the orientation of the Tool Centre Point also changes.
-90°
2
+z +y
+x 0°
+90°
Fig. 5-60 U-axis position
1. U-axis
2. Tool Centre Point
The procedure for setting the U-axis position is as follows:
Prerequisites:
▪ The homing offset (if any) is set (See section “Setting the homing offset”
for the detailed procedure).
procedure).
NOTICE
Setting incorrect U-axis position might lead to a crash during robot
operation.

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Procedure:
1. On the navigation bar, click the Shift tab. The Tool Compensation page
of the Shift screen appears.
Fig. 5-61 Tool Compensation page
2. On the Tool Compensation page, click the Edit key.
3. Under U-axis position, enter the required value (in degrees) in the U box.
Entering a value of 50 moves the U-axis to the 50° position.
The U-axis can move in a range of -90° to +90°. You can enter a
value between -90° to +90°.
4. Click the Save key to save the entered offset values.

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5.33 Setting the tool compensation

By default, the Tool Centre Point (TCP) is located at the centre of the robot
flange. With the tool compensation function, you can offset the TCP position
to compensate for changes in the tool dimensions (due to tool wear). This helps
to run an existing program on the robot without the need to teach all the points
in the program when the tool dimensions change.
3 +x
1
+y
+z
Fig. 5-62 Tool compensation
1. Tool Centre Point (before tool compensation)

2. Tool
3. Tool Centre Point (after tool compensation)
The procedure for setting the tool compensation is as follows:
Prerequisites:
procedure).
▪ The U-axis position (if used) is set (See section “Setting the U-axis position”
▪ The new dimensions of the tool are known.
NOTICE
Setting incorrect tool compensation might lead to a crash during robot
operation.

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Procedure:
1. Manually measure the difference in the old and new working points of the
tool.
4. Under Tool Compensation, enter the required offsets (in mm) for the TCP
along the respective axes (X and Z). Entering an offset for X shifts the TCP
by the set value along the X-axis.
It is not possible to shift the TCP along the Y-axis in a 5-axis robot.

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5.34 Tool calibration

By default, the origin of the tool co-ordinate system, TCP, is located at the
centre point of the robot flange. After mounting a tool into the robot flange, the
TCP can be shifted from the centre point of the robot flange to the working point
of the tool. This is called tool calibration. Tool calibration helps to:
▪ Move the working point of the tool in straight lines along the different axes.
▪ Move the tool about the TCP without changing the position of the TCP.
▪ Easily teach the different points in the robot program.
+x
1
2 +y
+z +x
3
+y
+z
Fig. 5-64 Tool calibration
1. Tool Centre Point (before tool calibration)

2. Tool
3. Tool Centre Point (after tool calibration)
The procedure for calibrating a tool is as follows:
Prerequisites:
procedure).
▪ The required tool is mounted in the robot flange.
NOTICE
Incorrect tool calibration might lead to a crash during robot operation.

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Procedure:
1. Manually measure and note down the distances (in mm) between the
working point of the new tool and the centre point of the robot flange (TCP)
along the different axes (X and Z).
4. Under Tool Compensation, enter the values as noted in Step 1 in the

respective boxes (X and Z). For example, enter the distance between the
working point of the tool and the centre of the robot flange along the X-
axis in the X box.
It is not possible to shift the TCP along the Y-axis in a 5-axis robot.
5.35 WORLD co-ordinate system

The WORLD co-ordinate system is a permanently fixed Cartesian co-ordinate
system. All movements of the robot are in the WORLD co-ordinate system.
5.36 Tool Centre Point (TCP)

The Tool Centre Point (TCP) is located at the centre point of the robot flange.
The Tool centre point can be offset by the user, depending on the dimensions
of the tool (See section “Tool calibration” for more information).

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5.37 Defining user frames

After creating a program, if the position of the work piece changes, you have
to teach all the points in the program all over again. But if you define user
frames, you don’t have to reprogram the robot and teach all the points in the
program again. With user frames, you can shift the start point (P1) of a program
to a newly taught start point. Based on the new defined start point, the relative
positions of the other points in the program are automatically interpolated.
Ry +Y
x1
x
y
z y1
z1
P1
P1
Rz
+Z Rx +X
Fig. 5-66 User frames
x: X co-ordinate of the old start point

y: Y co-ordinate of the old start point
z: Z co-ordinate of the old start point
x1: X co-ordinate of the new start point
y1: Y co-ordinate of the new start point
z1: Z co-ordinate of the new start point
Rx:Rotation about X-axis
Ry:Rotation about Y-axis
Rz: Rotation about Z-axis
The procedure for defining a user frame is as follows:
Prerequisites:
▪ The robot is in the Manual mode.
procedure).
▪ The required tool is installed in the robot flange.
▪ The tool compensation is set (See section “Setting the tool compensation”

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▪ The required program is open in the Program screen (See section

“Opening a program” for the detailed procedure).
NOTICE
Defining incorrect user frames might lead to a crash during robot
operation.
Procedure:
Defining a 1. Jog the robot in Linear mode till the Tool Centre Point (TCP) is at the new
user frame start point of the program (See section “Jogging the robot” for the detailed
procedure).
2. Note down the co-ordinates of this point from the Jog screen.
3. On the robot program structure tree on the Program screen, click the first
POINT instruction in the robot program.
4. Click the Command tab. The Command page for the POINT instruction
appears.
5. Note down the taught positions of the different axes (joints) for the selected
POINT. These are displayed under Teach Position.

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7. Click the User Frame tab. The User Frame page of the Shift screen
appears.
Fig. 5-69 User Frame page
8. On the User Frame page, click the Start Position key. The Start Position
window appears.
9. Click the Edit key.
10. Enter the X, Y, Z co-ordinates (in mm) of the starting point of the program
(as noted in Step 5) in the X, Y and Z boxes.
11. Click the Save key.

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12. Click the required User Frame # key (Four User Frames are available).
The selected User Frame window appears.
Fig. 5-70 User Frame page
13. Click the Edit key.
14. Enter the X, Y, Z co-ordinates (in mm) of the new start point of the program
(as noted in Step 2) in the X, Y and Z boxes.
15. Also enter the rotation of the new start point Rx, Ry and Rz about X, Y and
Z axes respectively.
16. Click the Save key. The start point shifts to the new point for the selected
User frame. The relative positions of the other points in the program is
automatically interpolated by the robot controller.
Selecting a 17. On the Program screen, add a SET instruction at the required step of the
user frame in the robot program structure where you want to change the user frame.
program
18. Select the SET instruction on the robot program structure.
19. Click the Command tab.
20. On the Set Variable box, set the condition as “Set Variable VR(941) = 1"
The user frame 1 is activated. The current start position of the program
shifts to the start position defined under user frame 1.
Set Variable V(942) = 1 for User frame 2

To deactivate the required user frame, Set the required variable to

0.

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5.38 Basic programs

5.38.1 Motion type - Line
In a line motion, the TCP moves from one point to another in a straight line
at the set speed and acceleration. You need to define two points (start and
end points) for this robot motion.The line motion can be programmed as
follows:
Prerequisites:
▪ The Program screen is opened after clicking the NEW PROGRAM icon
on the Main window.(See section “Creating a new program” for more
information).
Robot Program
Move - Linear P1 P2
P1
P2
Fig. 5-71 Motion type - Line
Procedure:

structure tree.
MOVE instruction 2. Add a MOVE instruction to the robot program structure. A POINT
instruction is automatically nested under the MOVE instruction (See
section “Creating a new program” for the detailed procedure).
3. On the Command page for this MOVE instruction, select Linear mode.
4. Set the Speed and Acceleration for the MOVE instruction in the Joint
Speed and Joint Acceleration boxes respectively.
Teaching the 5. Teach the start point (P1) in this POINT instruction (See section “Teaching
start point a point” for the detailed procedure).
6. Under the same MOVE instruction, add another POINT instruction.
Teaching the 7. Teach the end point (P2) in this POINT instruction (See section “Teaching
end point a point” for the detailed procedure).
The TCP moves in a straight line from point P1 to point P2.

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5.38.2 Motion type - Arc

The TCP of the robot can be programmed to move along an arc. Three points
(Start, mid and end points) must be defined to make the TCP trace an arc.
The start and end points must be in the same plane for this motion.
The procedure is as follows:
Prerequisites:
information).
Robot Program
Move - Linear
P2
P1
Move - Arc
P2 P1 P3
Move - Linear
P3
Fig. 5-72 Motion type - Arc
Procedure:

structure.
MOVE instruction 1 2. Add a MOVE instruction to the robot program structure. A POINT
MOVE instruction 2 6. Add another MOVE instruction to the robot program structure. A POINT
7. On the Command page for this MOVE instruction, select Arc mode.

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5 - Operation
Teaching the 9. Teach the mid point (P2) in this POINT instruction (See section “Teaching
mid point a point” for the detailed procedure).
Teaching the 13. Teach the end point (P3) in this POINT instruction (See section “Teaching
end point a point” for the detailed procedure).
The TCP moves along an arc from point P1 to point P3 because

of the Arc mode of point P2.
5.38.3 Motion type - Circular

The TCP of the robot can be programmed to move along a circular path. Three
points (Start point and two mid points) must be defined to make the TCP trace
a circle.
The start and midpoints must be in the same plane for this motion.
The procedure is as follows:
Prerequisites:
information).
P2
Robot Program
Move - Linear
P1
P1
Move - Arc
P2
P3
P3
Fig. 5-73 Motion type - Circle

©
5 - Operation
Procedure:

structure tree.
7. On the Command page for this MOVE instruction, select Arc mode.
Teaching the 9. Teach the mid point 1 (P2) in this POINT instruction (See section “Teaching
mid point 1 a point” for the detailed procedure).
Teaching the 11. Teach the mid point 2 (P3) in this POINT instruction (See section “Teaching
mid point 2 a point” for the detailed procedure).
The TCP moves along a circle from point P1 to point P1 because

of the Arc mode of points P2 and P3.

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5 - Operation
5.38.4 Motion type - Rectangle

The TCP of the robot can be programmed to move along a rectangle. Four
points (one start point and three corner points) must be defined to make the
TCP trace a rectangle. The procedure is as follows:
Prerequisites:
information).
Robot Program P1 P2
Move - Linear
P1
P2
P3
P4 P4 P3
Fig. 5-74 Motion type - Rectangle
Procedure:

structure tree.
MOVE instruction 2. Add a MOVE instruction to the robot program structure. A POINT
Teaching the 7. Teach the second corner point (P2) in this POINT instruction (See section
second corner “Teaching a point” for the detailed procedure).
point
Teaching the 9. Teach the third corner point (P3) in this POINT instruction (See section
third corner “Teaching a point” for the detailed procedure).
point

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5 - Operation
Teaching the 11. Teach the fourth corner point (P4) in this POINT instruction (See section
fourth corner “Teaching a point” for the detailed procedure).
point
The TCP traces a rectangle from point P1 to point P1 because of

the Linear mode of points P1, P2, P3 and P4.
5.38.5 Teaching a point

The procedure for teaching a point to the robot is as follows:
Prerequisites:
procedure).
▪ The required tool is installed in the robot flange.
▪ The tool is calibrated (See section “Calibrating the tool” for the detailed
procedure).
▪ The tool compensation is set (See section “Setting the tool compensation”
▪ A new program or an existing program is open in the Program screen (See
sections “Creating a new program” and “Opening a saved program” for
the detailed procedures).
▪ A MOVE instruction is added to the robot program structure (See section
“Creating a new program” for more information).
▪ The parameters for the MOVE instruction are set in the Command page
of the MOVE instruction (see section “MOVE” for more information).
▪ The required number of POINT instructions are added under the MOVE
instruction (see section “Creating a new program for more information”).
Procedure:
1. Select the required POINT instruction under the MOVE instruction in the
robot program.

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5 - Operation
2. Click the Command tab. The Command page for the POINT instruction
appears.
3. Click the Set this Point key. The Jog screen appears. Only the mode
(Linear or Joint) selected in the Command page of the MOVE instruction
is active.
Fig. 5-76 Jog screen
4. Jog the robot till the working point of the tool (on the robot flange) is at the
required position (See section “Jogging the robot” for the detailed
procedure).

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5 - Operation
5. Click the SAVE key. The Command screen of the POINT instruction
appears.The taught positions of the respective robot axes are displayed
in the Teach Position window in the Command page of the POINT
instruction.
6. Select the next in the robot program and repeat Steps 1 to 5 to teach the
point.

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5 - Operation
5.38.6 Using the Merge option and teaching a fillet profile

When you run a robot program, the robot stops at every point before moving
to the next point in the program. However, in some applications (e.g. sealant
dispensing), it is not desirable to stop the robot at every point before moving
to the next point. The Merge option on the Command page of the MOVE
instruction can be used to keep the robot moving continuously between points
without stopping at every point.
The following conditions must be satisfied when using the Merge option, to
achieve a smooth path profile:
▪ When the Merge option is activated, the MOVE instruction must contain
only one point. Every point should be defined under a separate MOVE
instruction.
▪ All MOVE instructions with Merge activated, must have a same speed.
▪ The Merge option must be used only in Linear mode.
▪ When the Merge option is used, it is necessary to use fillets on the corners.
When the robot moves continuously from one point to another in the Merge
option, there can be jerks and vibrations. The Merger (%) option (See
section “MOVE” for more information) makes the robot trace a smooth
curve (fillet) as it changes its axis of movement. This helps to dampen the
jerks and vibrations. Higher the value of the Merger (%) parameter, higher
is the radius of the fillet.The robot automatically interpolates the path by
converting the corner point into a smooth curve.
I II
P1 P2 P1 P2
P3 P3
P4 P5 P4 P5
Fig. 5-78 Robot paths
I. Robot path without Merger-option

II. Robot path with Merger-option
The procedure for teaching a fillet profile is as follows:

©
5 - Operation
Prerequisites:
information).
Robot Program
Move - Merger (0%)

P1 P2
P1
Move - Merger (50%)
P2
P3
Move - Merger (0%)
P3
Move - Merger (50%)
P4 P5
P4
Move - Merger (0%)
P5
Fig. 5-79 Teaching a fillet profile
Procedure:

structure tree.
4. Set the Speed and Acceleration of the movement during the MOVE
instruction in the Joint Speed and Joint Acceleration boxes respectively.
5. Select the Merge option and set the Merger value to 0%.
Teaching the 6. Teach the point 1 (P1) in this POINT instruction (See section “Teaching
point 1 a point” for the detailed procedure).

©
5 - Operation
9. Set the same Speed and Acceleration for this MOVE instruction as set
for the first MOVE instruction.
10. Select the Merge option and set the Merger value to the required value,
depending on the radius of the fillet (e.g. 50%).
15. Select the Merge instruction and set the Merger value to 0%.
20. Select the Merge option and set the Merger value to the required value,
depending on the radius of the fillet (e.g. 50%).
23. On the Command screen for this MOVE instruction, select Linear mode.
25. Select the Merge option and set the Merger value to 0%.

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5 - Operation
The TCP moves from point P1 to point P5 along the path as shown
in the illustration above. Points P2 and P4 are bypassed to form
a smooth fillet profile towards the next point.
5.39 Switching user levels

You can switch between user levels (Admin and Operator) as follows:
Prerequisites:
Procedure:
appears.
2. Click the Switch User key. The Login screen appears.
3. Login to the teach pendant application with the desired user level (See

©
5 - Operation
5.40 Exiting the teach pendant application

You can exit the teach pendant application as follows:
Prerequisites:
Procedure:
appears.
2. Click the Exit key. The teach pendant application closes and the Desktop
page appears.

©
5 - Operation
5.41 Restarting the teach pendant application

The teach pendant application starts automatically when you switch ON the
robot. The application must be manually restarted only when you exit the
application. The procedure for restarting the teach pendant application is as
follows:
Procedure:
1. Double-click the Teach Pendent.exe file. The teach pendant application

loading screen appears as the teach pendent application loads. The Login
screen appears after the application has loaded.
Fig. 5-84 Teach pendant application loading screen

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5 - Operation
Fig. 5-85 Login screen
5.42 Viewing the teach pendant application details

You can view the teach pendant application details as follows:
Procedure:
appears.
Fig. 5-86 Teach pendant application details
2. Click the About key. A window with the teach pendant application details
appears.

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5 - Operation
5.43 Upgrading the teach pendant application

The teach pendant application can be updated to a new version as follows:
Prerequisites:
Procedure:
Uninstalling the teach 1. Exit the teach pendant application. The Desktop page appears. (See
pendant application section “Exiting the teach pendant application” for the detailed
information).
2. On the Desktop page, go to My Device>Program Files
3. Double-click the TP_Uninstaller. exe icon. A confirmation window

appears.
Fig. 5-88 Uninstalling the teach pendant application

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5 - Operation
4. Click Uninstall. The Teach pendant application is uninstalled.
Installing the new teach 5. Copy the TeachPendentInstaller.CAB file (from TAL) from the USB
pendant application device to My Device>Program Files.
6. Double-click the TeachPendantInstaller.CAB icon. The new teach

pendant application is installed. The Teach Pendent.exe icon gets added
to the Program Files folder.
Fig. 5-89 Installing the teach pendant application
7. Double-click the Teach Pendent.exe icon to load the Teach pendant

application.

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5 - Operation
5.44 Changing the password of the teach pendant application

You can change the password of the teach pendant application as follows:
Prerequisites:
Procedure:
1. Exit the teach pendant application. The Desktop page appears. (See
section “Exiting the teach pendant application” for the detailed
information).
2. On the Desktop page, go to My Device>Program Files
3. Double-click the TPassword. exe icon. The Password window appears.
Fig. 5-91 Changing the password of the teach pendant application

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5 - Operation
4. Enter the old password in the Old Password box.
5. Enter the new password into the New Password and Confirm Password
boxes.
6. Click Apply to apply the new password.
5.45 Shutting down the robot

You can shut down the robot as follows:
Prerequisites:
▪ The current program is closed.
Procedure:
1. Turn the Main switch (1) on the robot controller (2) counterclockwise to
OFF position. The POWER ON lamp (3) stops glowing. The robot is now
switched OFF.
Fig. 5-92 Switching OFF the robot
2. Turn OFF the power supply to the robot controller.

©
6 - Maintenance
6 Maintenance
6.1 General safety and precautions

▪ Turn OFF the main power switch on the robot controller and secure it with
a padlock before starting any maintenance or repair function.Do not enter
the workspace of the robot or the enclosed area when the robot is in
switched ON condition.
▪ Strictly observe all mandatory safety regulations that are currently in force
while performing maintenance work.
▪ Allow only authorised and skilled personnel to carry out maintenance work
on the machine.
▪ If the robot has been operational for a long time, wait for the motors and
the robot controller to cool down to normal temperature before starting any
maintenance or repair tasks.
▪ Make sure that there is enough space and sufficient lighting in the
maintenance area.
▪ After a maintenance function and before you connect the robot to the power
supply, make sure that all cables and the earthing wire are correctly
connected.
▪ Make sure that all safety devices are connected before you switch ON the
robot after a maintenance function.
DANGER
power.
electrical parts.

©
6 - Maintenance
DANGER
Fire hazard.
Risk of severe burns due to fire.
– Do not keep any flammable items in the robot
workspace.
– If any electrical insulation is damaged, repair
the insulation or replace the parts.
– Use a carbon dioxide extinguisher to extinguish
the fire.
WARNING
WARNING
Hot surfaces.
Risk of burns to skin.
– Do not touch the hot surfaces of the robot.
– Carry out maintenance activity only after the
robot components have cooled down to normal
temperature.
– Wear protective hand gloves.
6.2 Tools required for maintenance

The following tools, equipment, and supplies are required to do maintenance
work on the robot:
▪ Standard tool box

▪ Allen key set from M3 to M12
▪ Multimeter
▪ Some lint-free cloth
6.3 Recommended spares

Use only genuine parts and spares from TAL. It is recommended to have the
following spares ready at hand to facilitate a fast repair and to minimise the
downtime:
1. Tensioners of axes 4 and 5

2. Tensioner of axis 3
3. Stage-1 belt of axes 2 and 3

©
6 - Maintenance
6.4 Maintenance and lubrication schedules

6.4.1 Daily maintenance
Number Position Activity/Maintenance function

1 Robotic arm ▪ Clean the robotic arm with a soft and dry
cloth.
▪ Remove all product or process
residues from the workspace.
▪ Check for any abnormal vibrations,
noise, or heat generated in motors
during operations.
▪ Check for any cracks or dust on the
equipment's electrical parts.
2 Robot controller ▪ Clean the outer surface of the robot
controller with a soft and dry cloth.
▪ Check for the correct functioning of the
cooling fans.
equipment's electrical parts.
▪ Make sure that cooling fans are running
when the robot controller door is closed
and there is no excessive heat inside
the cabinet.
3 Teach pendant ▪ Clean the teach pendant with a soft
cloth.
NOTICE
Do not use benzene or other thinners to clean the robot.

©
6 - Maintenance
6.4.2 Quarterly maintenance

1 General ▪ Check all the connectors (power,
encoder, teach pendant) and make
sure they are tightly connected at both
ends.
robot's electrical parts.
▪ Check the earthing screws for any
deposits and remove them with a brush
or file.
2 Robotic arm ▪ Check that the connectors to the drive
motors are not loose.
▪ Check that the screws that secure the
robotic arm covers are not loose.
3 Bevel gears ▪ Apply grease (Veedol) on the bevel
inside the robotic gears of the robotic hand. For more
hand details, refer to the following section.
4 Robot controller ▪ Clean the filters of the inlet and exhaust
fans.
▪ Check for the correct functioning of the
cooling fans.
▪ Check whether the electrical
connections inside the robot controller
cabinet are loose.
Greasing the bevel gears of the robotic hand

The procedure for greasing the bevel gears of the robotic hand is as follows:
Prerequisites:
▪ The robot is switched OFF.

Tools required:
▪ Allen key set
Procedure:
1. Loosen and remove the two M4 Allen screws (1) and the three M3 Allen
screws (2) on the cover (3) of the robotic hand.
2. Remove the covers of the robotic hand.

©
6 - Maintenance
3. Apply grease with a brush on the bevel gears (4).
2
1 4
Fig. 6-1 Greasing the bevel gears of the robotic hand
4. Mount the covers of the robotic hand.
5. Insert and tighten the two M4 Allen screws (1) and the three M3 Allen
screws (2) on the cover. Tighten the screws to the correct tightening torque.
See section “Recommended tightening torque for screws” in the “Product
description” chapter for information about the recommended tightening
torques of different screws.
6.4.3 Half-yearly maintenance

1 Drive belts of the ▪ Inspect for any defects (To be done by
motors inside the TAL service engineers).
robotic arm ▪ Replace the belts after 8000 hours of
use.

©
6 - Maintenance
6.5 Troubleshooting
6.5.1 Common errors and solutions
Symptom Cause Remedy

Abnormal heat ▪ Inlet or exhaust fan ▪ Check if the MCB of the
generation in failure. fans are tripped.
control panel. ▪ Fan or fan cover ▪ Check for the cause of
jammed. jam and remove the
▪ Fan filter blocked. obstacles.
▪ Clean filter.
Motors of the ▪ No power. ▪ Check the connections.
robotic arm is ▪ Fault condition exists. Turn ON the power.
not rotating. ▪ Check the drive status.
Erratic motor ▪ Control signal is too ▪ Check drive
condition. weak. parameters.
▪ Control signal is ▪ Check input power.
interfered.
▪ Faulty motor coil.
▪ Motor capacity is
inadequate for the
application.
▪ Acceleration is too high.
▪ Power supply is
irregular.
Excessive ▪ Inadequate cooling. ▪ Check for the proper
heating of the ▪ Load is too high. working of fans.
drives and ▪ Check input power.
motors.
Unable to do ▪ Position of the robot is ▪ Jog the robot to pre-
the homing not suitable for homing homing position.
procedure. procedure. ▪ Check sensors.
▪ Sensors are faulty. ▪ Check connections.
▪ Loose connections. Tighten, if required.
Error message ▪ Communication ▪ Contact TAL customer
on teach mismatch between the service.
pendant - robot controller and
Waiting for the teach pendant.
acknowledgem ▪ Teach pendant software
ent from and robot controller
Controller. software versions are
incompatible.
Teach pendant ▪ Loose connections. ▪ Check connections.
- Tighten, if required.
Communicatio ▪ If unresolved, contact
n error. TAL customer service.

©
6 - Maintenance
6.5.2 Fault list

The error messages that occur on the drives are displayed on the teach
pendant screen under the Error log tab. The following details are displayed
on the Error log screen:
1. Axis number - Displays the number of axis (for example, A02) where the
error occurs.
2. Error type - Displays the type of error. For a detailed list of error type, refer
to the following table.
3. Error time - Displays the time at which the error occurred.
4. Error code - Displays the description of the error. For a detailed list of error
codes, refer to the Description column of the following table.
5. Axis FE - Displays the master following error on the axis at the time the
error occurred.
6. Axis MSpeed - Displays the master measured speed on the axis at the time
the error occurred.
The error type, error code and their solution are listed in the following table:
Error type Error code Solution

(Description)
0 No error --
1 Drive following error ▪ Check whether the encoder
connections are loose.
▪ Check the Earth to Neutral
voltage. This must be less than
2V/1Ohm.
▪ Check whether the panel
condition is as per EMC norms.
▪ Check whether the motor
winding connection is
connected incorrectly.
▪ Check for any obstacles during
the robot motion.
2 Master following error ▪ Abnormal motion of robot
detected by Master.
▪ Check the encoder cable
connections and EMC norms of
the panel.
▪ Check whether the motor
winding connection is
connected incorrectly.
2V/1Ohm.
3 High voltage failure ▪ Check the input voltage.
▪ We recommend to use regulated
supply to avoid voltage surges.

©
6 - Maintenance
Error type Error code Solution

(Description)
4, Thermal protection ▪ Check whether the fans are
17168 working properly. Specifically
check whether the airflow
direction is from bottom to top.
▪ Check the temperature inside
the robot controller. Let the robot
controller cool down for some
time.
5, Communication error ▪ Check the cable connections
65535 (ETHERCAT-CAT5) between
the drives and the controller.
▪ Check the temperature inside
the robot controller. Let the robot
controller cool down for some
time.
6, Abnormal encoder jump ▪ Check whether the encoder
65534 cable connections are loose.
2V/1Ohm.
8496 ▪ Short circuit ▪ Check the input voltage.
▪ Abnormal current on ▪ We recommend to use regulated
the motor phase. supply to avoid voltage surges.
20736 High voltage out of ▪ Check the input voltage.
range ▪ We recommend to use regulated
supply to avoid voltage surges.
34321 Following error ▪ Refer to the drive following error
(Displays U00 if it is a and master following error
drive following error and solutions mentioned earlier in
Axx, where xx is the axis this table.
number, if it is an axis
following error.)

©
7 - Decommissioning and disposal
7 Decommissioning and disposal

After decommissioning at the end of its service life, the robot and connected
equipment must be disposed off in accordance with the applicable national
laws, regulations and standards. TAL BRABO robots are manufactured with
minimal use of hazardous substances to protect the environment. TAL
recommends leaving the disposal to a local disposal company authorised to
provide the necessary certificates verifying proper disposal.

©
7 - Decommissioning and disposal

©
8 - Warranties and certifications
8 Warranties and certifications
8.1 Product warranty

The Seller warrants that the Products supplied under the Contract are as per
agreed specifications and incorporate all recent improvements in design and
materials unless provided otherwise in the Contract. The Seller further
warrants that the Products supplied under the Contract are free from
manufacturing defects and suitable for specified uses under specified
conditions. The warranty period shall remain valid for 12 months from the date
of commissioning of the Seller.The Buyer shall promptly notify the Seller in
writing of any claims arising under this warranty. Upon receipt of such notice,
the Seller shall, with all reasonable speed, repair or replace the defective
Products, without costs to the Buyer. This does not include normal wear items
of consumables and those items, which are made of glass, plastics and rubber,
etc. The warranty for electrical and electronic items is subject to quality of
power, proper relays, etc. as required for optimum functioning of the Products,
as specified in the standard operating manuals of the products and any
deviation from the standard operating manual will void the warranty clause.
The Seller offers only limited warranty as obtained from the original
manufacturer for bought out items and any issues regarding such bought out
items may be directly referred to original manufacturer for replacement / repair
on the terms as offered by the original manufacturer. The warranty of the Seller
shall be void if the Products are not integrated with other machines as per the
standard operating manual.Only genuine spare parts, accessories,
consumables, etc recommended / manufactured by the Seller shall be used
in the Products to claim its performance & warranty. Any variations to the same
by the Buyer and/or any violation of this GTC shall render the Seller's warranty
void.The Warranty does not extend beyond Seller's applicable standard
specifications of Products as contained in the Quotations/Contracts or in the
standard operating manual.
The Product shall:

a. Unless otherwise provided elsewhere in these GTC be of merchantable
quality within the meaning of the Indian "Sale of Goods Act, 1930"; and
b. Be reasonably fit for the purpose for which the Products are being bought,
if the Buyer had made known that purpose to the Seller in writing subject
to strict adherence of the standard operating manual of the Product.
The Seller shall not be liable for a breach of any of the warranties in condition
aforesaid unless:
a. The Buyer gives written notice of manufacturing defect to the Seller within
7 working days of the time when the Buyer discovers or ought to have
discovered the manufacturing defect within warranty period; and
b. The Seller is given reasonable opportunity after receiving the notice for
the examination of such Products and the Buyer (if asked to do so by the
Seller) returns such Product to the Seller's place of business at Buyer's
cost for the examination to take place there.

©
The Seller shall not be liable for a breach of any of the warranties in condition if:
a. The defect in Products arises from any drawing, design or specification
supplied by the Buyer for application or
b. The total Contract Price of Products has not been paid; or
c. The defect arises due to any accident, neglect or misuse, unsuitable
storage, improper quality of power, power breakdown, power fluctuations
within +/-10%, power supply free from spikes/surges, power factor below
unity, non-uniform phase load distribution, improper handling, improper
maintenance, abnormal working conditions, damage in transit, faulty
operations, use contrary to instruction/operating manual, spurious spare
parts used in the product or damaging due to external influences of a
physical, electrochemical or chemical nature or otherwise in contravention
of Product trade practice; or
d. The Buyer alters/changes/modifies, repairs, or parts with the Product
without the written consent of the Seller.
All warranties, conditions and other terms implied by the statute or common
law are, to the fullest extent permitted by the law, excluded from the Contract.

©
8.2 EC declaration of conformity

©

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Operating Manual

Copyright © 2017 TAL Manufacturing Solutions Limited.

1 About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

3 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 CAN 16 I/O module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4 Transport and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5.7 Homing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.38.1 Motion type - Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

7 Decommissioning and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 Warranties and certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

1 About this documentation

1.2 Intended users

1.3 Important safety notice

▪ Do not operate the robot without a safety enclosure or safety fence.

Operating Manual V1 TAL BRABO 1-1

1.4 Conventions used in this manual

1-2 TAL BRABO Operating Manual V1

Teach pendant The teach pendant is a device with a touchscreen,

1.5.1 Acronyms and initialisms

Operating Manual V1 TAL BRABO 1-3

1.7 Language of instructions

1.8 Copyrights and trademarks

1.9 Manufacturer’s address

1.10 Customer support

1-4 TAL BRABO Operating Manual V1

2.1 Intended use

▪ Using the robot without performing a risk assessment of the complete

Operating Manual V1 TAL BRABO 2-1

2.2 Limitation of liability

2.3 Applicable safety standards

▪ ISO 10218-1: Safety requirements for industrial robots - Part 1: Robots

2-2 TAL BRABO Operating Manual V1

2.4 General safety information

Integration to other systems

Safety during installation and service

Operating Manual V1 TAL BRABO 2-3

▪ Make sure that safety measures and robot safety configuration

Safety during operation

2-4 TAL BRABO Operating Manual V1

2.5 General safety symbols

Operating Manual V1 TAL BRABO 2-5

2.6 Safety symbols on the robot

2.6.1 Safety symbols on the robotic arm

Fig. 2-1 Safety symbols on the robotic arm

2-6 TAL BRABO Operating Manual V1

2.6.2 Safety symbols on the robot controller and teach pendant

Operating Manual V1 TAL BRABO 2-7

Fig. 2-3 Safety symbols inside the robot controller

2.7 Risk assessment

▪ ISO 10218-1:2011 Robots and robotic devices - Safety requirements for

2-8 TAL BRABO Operating Manual V1

2.8 Workspace and safety zone

Operating Manual V1 TAL BRABO 2-9

The workspace of the robot is as shown in the following figure:

Fig. 2-4 Workspace of the robot (All dimensions are in mm)

2-10 TAL BRABO Operating Manual V1

2.9 Safety systems on the robot

1. Main power switch on the robot controller

Operating Manual V1 TAL BRABO 2-11