s4cplus-product manual irb 6400r m2000_rev02

8/9/2019 S4CPlus-Product Manual IRB 6400R M2000_rev02

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Product Manual

3HAC 7677-1

IRB 6400R

M2000/Rev. 2


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The information in this document is subject to change without notice and should not be construed as acommitment by ABB Automation Technology Products AB, Robotics. ABB Automation TechnologyProducts AB, Robotics assumes no responsibility for any errors that may appear in this document.

In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental orconsequential damages arising from use of this document or of the software and hardware describedin this document.

This document and parts thereof must not be reproduced or copied without ABB AutomationTechnology Products AB, Roboticss written permission, and contents thereof must not be imparted toa third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB Automation Technology Products AB,Robotics at its then current charge.

ABB Automation Technology Products AB


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1 Introduction / System Description

2 Product Specifications

3 Safety

4 Certificates

5 Configuration List

6 Decomissioning

7 Description

8 Installation and Comissioning

9 Maintenace and Repairs

10 Fault Tracing Guide

11 Spare Parts List

12 Circuit Diagram

13 Installation and Comissioning

14 Maintenance

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Introduction

CONTENTSPage

1 Introduction ....................................................................................................... 3

1.1 How to use this Manual ............................................................................. 3

1.2 What you must know before you use the Robot........................................ 3

1.3 Identification .............................................................................................. 4

1.4 Structure Manipulator ................................................................................ 6

1.5 Structure Controller ................................................................................... 111.6 Electronics unit .......................................................................................... 11

1.6.1 The computer system consists of the following parts: ..................... 12
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This manual provides information on installation, preventive maintenance,troubleshooting, and how to carry out repairs on the manipulator and controller.Its intended audience is trained maintenance personnel with expertise in bothmechanical and electrical systems. The manual does not in any way assume to

take the place of the maintenance training course offered by ABB FlexibleAutomation.

Anyone reading this manual should also have access to the Users Guide.

The chapter entitled System Description provides general information on therobot structure, such as its computer system, input and output signals, etc.

How to assemble the robot and install all signals, etc., is described in the chapteron Installation and Commissioning.

If an error should occur in the robot system, you can find out why it hashappened in the chapter on Troubleshooting. If you receive an error message,you can also consult the chapter on System and Error Messages in the UsersGuide. It is very helpful to have a copy of the circuit diagram at hand whentrying to locate cabling faults.

Servicing and maintenance routines are described in the chapter onMaintenance.

Usually requires only standard tools. Some repairs, however, require specifictools. These repairs and the type of tool required, are described in more detail inthe chapter Repairs.

Must always be switched off whenever work is carried out in the controllercabinet. Note that even though the power is switched off, the orange-colouredcables may be live. The reason for this is that these cables are connected to


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Identification plates indicating the type of robot and serial number, etc., are located onthe manipulator (see Figure 1) and on the front of the controller (see Figure 2).

Note! The identification plates and label shown in the figures below, only serve asexamples. For exact identification see the plates on the robot in question.

Identification plate showithe IRB 6400R / M2000

Made in SwedenS-721 68 Vsters Sweden

IRB 6400R M2000

IRB 6400R/2.5-150

XXXXXX

See instructions

2000-XX-XX

2,8-150 : 2240 kg

2,8-200 : 2390 kg

3.0-100 : 2250 kg

Type:

Robot version:

Man. order:

Nom. load

Serial. No:

Date of manufacturing:

Net weight

2,5.120 : 2060 kg

2.5-150 : 2060 kg

2,5-200 : 2230 kg


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.

Made in SwedenS-721 68 Vsters Sweden

ABB Robotics Products AB

Type:

Robot version:

Voltage: 3 x 400 V

Power:

Man. order:

Re.No:

Serial. No:

Date of manufacturing:

Net weight:

IRB 6400R M2000

IRB 6400R/2.5-150

Frequency: 50-60 Hz

7.2 kVA

XXXXXX

RXXXXXXXXXX

64-XXXXX

2000-XX-XX

240 kg


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The robot is made up of two main parts, the manipulator and controller. Thecontroller is described in section 1.5.

The Manipulator is equipped with maintenance-free AC motors, which haveelectromechanical brakes. The brakes lock the motors when the robot is inoperativefor more than 1000 hours. The time can be configured by the user.

The following figures show the various ways in which the different manipulatorsmove and their component parts.


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.


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The controller, which contains the electronics used to control the manipulator andperipheral equipment, is specifically designed for robot control and consequentlyprovides optimal performance and functionality.

Figure 11shows the location of the various components on the cabinet.

All control and supervisory electronics, apart from the serial measurement board thatis located inside the manipulator, are gathered together inside the controller.

Manipulatorconnection

Mains switch

Teach pendant

Operators panel

Service outlet

ComputerSystem

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Link

Driveun

it3

Driveun

it2

Driveun

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One Main computer slot and 7 PCI slots.

Controls the entire robot system. Intel PentiumTM

- CPU. 32 MB DRAM. 10/100 Mb, 7/s Ethernet controller.

64 Mb Flash disk, (Optional 128 Mb).

Control of the manipulator motors.

Handles I/O communication (CAN, Ethernet, serial links).

Handles external axis and I/O computers, field bus communication, etc.

Four regulated and short-circuit-protected output voltages (12V, 5V, 3.3V).24V DC Input.

Rechargeable NiCd battery and battery management card.


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230V AC supply, distributes DC power to computer system.

Gathers and coordinates all signals that affect operational and personal safety.

Enables communication with external equipment by means of digital inputs andoutputs, analog signals, or field buses.

I/O units can alternatively be located outside the cabinet. Communication with robotdata is implemented via a stranded wire CAN bus which allows the units to be

I/O units (x4)

AC connection

Motors On and brake contactors Floppy disk (Opt.)

Connector

Panel unit

Computer System


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- Axis computer Drive and Measurement System.

- I/O computer Serial ports, CAN bus, Safety system, TPU.

- Extra axis computer D and M Sys.

- Extra I/O computer Serial parts, CAN bus.


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Safety

Contents page

1 Safety 1

1.1 General............................................................................................ 1

1.1.1 Introduction .......................................................................... 1

1.2 Applicable Safety Standards ........................................................... 1

1.3 Fire-Extinguishing............................................................................ 1

1.4 Definitions of Safety Functions........................................................ 2

1.5 Safe Working Procedures ............................................................... 2

1.5.1 Normal operations ............................................................... 2

1.6 Programming, Testing and Servicing............................................... 3

1.7 Safety Functions.............................................................................. 3

1.7.1 The safety control chain of operation................................... 3

1.7.2 Emergency stops ................................................................. 4

1.7.3 Mode selection using the operating mode selector.............. 4

1.7.4 Programming and testing at reduced speed........................ 5

1.7.5 Testing at full speed ............................................................. 5

1.7.6 Automatic operation............................................................. 5

1.7.7 Enabling device ................................................................... 6

1.7.8 Hold-to-run control ............................................................... 61.7.9 General Mode Safeguarded Stop (GS) connection ............. 6

1.7.10 Automatic Mode Safeguarded Stop (AS) connection .......... 7

1.7.11 Limiting the working space................................................... 7

1.7.12 Supplementary functions ..................................................... 7

1.8 Safety Risks Related to End Effectors ............................................ 8

1.8.1 Gripper................................................................................. 81.8.2 Tools/workpieces ................................................................. 8

1.8.3 Pneumatic/hydraulic systems .............................................. 8

1.9 Risks during Operational Disturbances........................................... 8

1 10 Ri k d i I t ll ti d S i 8


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Safety Contents

page


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Safety

1 Safety

1.1 General

This information on safety covers functions that have to do with the operation of theindustrial robot.

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 totalsystem.

To protect personnel, the complete system must be designed and installed inaccordance with the safety requirements set forth in the standards and regulations ofthe country where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicablesafety laws and regulations in the country concerned are observed and that the safetydevices necessary to protect people working with the robot system have been designed

and installed correctly.People who work with robots must be familiar with the operation and handling of theindustrial robot, described in the applicable documents, e.g. Userss Guide andProduct Manual.

The diskettes which contain the robots control programs must not be changed inany way because this could lead to the deactivation of safety functions, such asreduced speed.

1.1.1 Introduction

Apart from the built-in safety functions, the robot is also supplied with an interface forthe connection of external safety devices.

Via this interface, an external safety function can interact with other machines andperipheral equipment. This means that control signals can act on safety signalsreceived from the peripheral equipment as well as from the robot.

In the Product Manual -Installation and Commissioning,instructions are provided forconnecting safety devices between the robot and the peripheral equipment.

1.2 Applicable Safety Standards


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Safety Safety

1.4 Definitions of Safety Functions

Emergency stop IEC 60204-1, 10.7

A condition which overrides all other robot controls, removes drive power from robotaxis actuators, stops all moving parts and removes power from other dangerousfunctions controlled by the robot.

Enabling device ISO 11161, 3.4

A manually operated device which, when continuously activated in one position only,allows hazardous functions but does not initiate them. In any other position, hazardousfunctions can be stopped safely.

Safety stop ISO 10218 (EN 775), 6.4.3

When a safety stop circuit is provided, each robot must be delivered with thenecessary connections for the safeguards and interlocks associated with this circuit. Itis necessary to reset the power to the machine actuators before any robot motion can

be initiated. However, if only the power to the machine actuators is reset, this shouldnot suffice to initiate any operation.

Reduced speed ISO 10218 (EN 775), 3.2.17

A single, selectable velocity provided by the robot supplier which automaticallyrestricts the robot velocity to that specified in order to allow sufficient time for peopleeither to withdraw from the hazardous area or to stop the robot.

Interlock (for safeguarding) ISO 10218 (EN 775), 3.2.8

A function that interconnects a guard(s) or a device(s) and the robot controller and/orpower system of the robot and its associated equipment.

Hold-to-run control ISO 10218 (EN 775), 3.2.7

A control which only allows movements during its manual actuation and which causesthese movements to stop as soon as it is released.

1.5 Safe Working Procedures

Safe working procedures must be used to prevent injury. No safety device or circuitmay be modified, bypassed or changed in any way, at any time.


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Safety Safety

If any contact in the safety chain of operation opens, the robot always reverts to theMOTORS OFF mode. The MOTORS OFF mode means that drive power is removed

from the robots motors and the brakes are applied.

Figure 1 Safety control chain of operation

The status of the switches is indicated by LEDs on top of the panel unit in the controlcabinet and is also displayed on the Teach Pendant Unit (I/O window).

After a stop, the switch must be reset at the unit which caused the stop, before therobot can be ordered to start again.

The safety chains must never be bypassed, modified, or changed in any other way.

1.7.2 Emergency stops

An emergency stop should be activated if there is a danger to people or equipment.Built-in emergency stop buttons are located on the operators panel of the robot

controller and on the Teach Pendant Unit.External emergency stop devices (buttons, etc.) can be connected to the safety chainby the user (see Product Manual -Installation and Commissioning). They must beconnected in accordance with the applicable standards for emergency stop circuits.

Before commissioning the robot, all emergency stop buttons or other safety equipmentmust be checked by the user to ensure their proper operation

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K1 K2

LIM1 LIM2 ES2ES1

GS1 GS2 AS2AS1

TPU

En1

TPU

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Man2Man1

Auto1 Auto2

K1 K2

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Externalcontactors

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Safety Safety

One automatic and two manual modes are available:

The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters therobots safeguarded space. The robot must be operated using the Teach Pendant Unitand, if 100% is selected, using Hold-to-run control.

In automatic mode, the operating mode selector is switched to , and all safetyarrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,are active. Nobody may enter the robots safeguarded space. All controls, such asemergency stops, the control panel and control cabinet, must be easily accessible fromoutside the safeguarded space.

1.7.4 Programming and testing at reduced speed

Robot movements at reduced speed can be carried out as follows:

1. Set the operating mode selector to


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Safety Safety

1.7.7 Enabling device

When the operating mode selector is in the MANUAL or MANUAL FULL SPEEDposition, the robot can be set to the MOTORS ON mode by depressing the enablingdevice on the Teach Pendant Unit.

Should the robot revert to the MOTORS OFF mode for any reason while the enablingdevice is depressed, the latter must be released before the robot can be returned to theMOTORS ON mode again. This is a safety function designed to prevent the enablingdevice from being rendered inactive.

When the enabling device is released, the drive power to the motors is switched off,the brakes are applied and the robot reverts to the MOTORS OFF mode.

If the enabling device is reactivated, the robot changes to the MOTORS ON mode.

1.7.8 Hold-to-run control

This function is always active when the operating mode selector is in the MANUAL

FULL SPEED position. It is possible to set a parameter to make this function activealso when the operating mode selector is in the MANUAL position.

When the Hold-to-run control is active, the enabling device and the Hold-to-runbutton on the Teach Pendant Unit (TPU) must be depressed in order to execute aprogram. When the button is released, the axis (axes) movements stop and the robotremains in the MOTORS ON mode.

Here is a detailed description of how to execute a program in Hold-to-run control:

1. Activate the enabling device on the TPU.

2. Choose execution mode using the function keys on the TPU:

- Start(continuous running of the program)

- FWD(one instruction forwards)

- BWD(one instruction backwards)

3. Wait for the Hold-to-run alert box.

4. Activate the Hold-to-run button on the TPU.Now the program will run (with the chosen execution mode) as long as the Hold-to-run button is pressed. Releasing the button stops program execution and activating thebutton will start program execution again.

For FWD and BWD execution modes, the next instruction is run by releasing and

Safety


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Safety Safety

curtains, light beams or sensitive mats. The GS is active regardless of the position ofthe operating mode selector.

When this connection is open the robot changes to the MOTORS OFF mode. To resetto MOTORS ON mode, the device that initiated the safety stop must be interlocked inaccordance with applicable safety regulations. This is not normally done by resettingthe device itself.

1.7.10 Automatic Mode Safeguarded Stop (AS) connection

The AS connection is provided for interlocking external safety devices, such as lightcurtains, light beams or sensitive mats used externally by the system builder. The ASis especially intended for use in automatic mode, during normal program execution.

The AS is bypassed when the operating mode selector is in the MANUAL orMANUAL FULL SPEED position.

1.7.11 Limiting the working space

Note! Not valid for IRB 340(r) and IRB 140

For certain applications, movement about the robots main axes must be limited inorder to create a sufficiently large safety zone. This will reduce the risk of damage tothe robot if it collides with external safety arrangements, such as barriers, etc.

Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or bymeans of electrical limit switches. If the working space is limited by means of stops or

switches, the corresponding software limitation parameters must also be changed. Ifnecessary, movement of the three wrist axes can also be limited by the computersoftware. Limitation of movement of the axes must be carried out by the user.

1.7.12 Supplementary functions

Functions via specific digital inputs:

- A stop can be activated via a connection with a digital input. Digital inputscan be used to stop programs if, for example, a fault occurs in the peripheralequipment.

Functions via specific digital outputs:

E i di f l i h b

Safety S f t


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Safety Safety

1.8 Safety Risks Related to End Effectors

1.8.1 Gripper

If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece mustbe prevented.

1.8.2 Tools/workpiecesIt must be possible to turn off tools, such as milling cutters, etc., safely. Make sure thatguards remain closed until the cutters stop rotating.

Grippers must be designed so that they retain workpieces in the event of a powerfailure or a disturbance of the controller. It should be possible to release parts bymanual operation (valves).

1.8.3 Pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy may be present in these systems so, after shutdown, particular caremust be taken.

The pressure in pneumatic and hydraulic systems must be released before starting torepair them. Gravity may cause any parts or objects held by these systems to drop.Dump valves should be used in case of emergency. Shot bolts should be used toprevent tools, etc., from falling due to gravity.

1.9 Risks during Operational Disturbances

If the working process is interrupted, extra care must be taken due to risks other thanthose associated with regular operation. Such an interruption may have to be rectifiedmanually.

Remedial action must only ever be carried out by trained personnel who are familiarwith the entire installation as well as the special risks associated with its differentparts.

The industrial robot is a flexible tool which can be used in many different industrialapplications All work must be carried out professionally and in accordance with

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Safety Safety

Note! To prevent injuries and damage during the installation of the robot system, theregulations applicable in the country concerned and the instructions of ABB

Robotics must be complied with.Special attention must be paid to the following points:

- The supplier of the complete system must ensure that all circuits used in thesafety function are interlocked in accordance with the applicable standardsfor that function.

- The instructions in the Product Manual -Installation and Commissioningmust always be followed.

- The mains supply to the robot must be connected in such a way that it can beturned off outside the robots working space.

- The supplier of the complete system must ensure that all circuits used in theemergency stop function are interlocked in a safe manner, in accordance withthe applicable standards for the emergency stop function.

- Emergency stop buttons must be positioned in easily accessible places so that

the robot can be stopped quickly.- Safety zones, which have to be crossed before admittance, must be set up in

front of the robots working space. Light beams or sensitive mats are suitabledevices.

- Turntables or the like should be used to keep the operator away from therobots working space.

- Those in charge of operations must make sure that safety instructions are

available for the installation in question.

- Those who install the robot must have the appropriate training for the robotsystem in question and in any safety matters associated with it.

Although troubleshooting may, on occasion, have to be carried out while the powersupply is turned on, the robot must be turned off (by setting the mains switch to OFF)when repairing faults, disconnecting electric leads and disconnecting or connectingunits.

Even if the power supply for the robot is turned off, you can still injure yourself.

- The axes are affected by the force of gravity when the brakes are released. Inaddition to the risk of being hit by moving robot parts, you run the risk ofbeing crushed by the tie rod.

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Safety Safety

1.11 Dimensioning the safety fence

A safety fence must be fitted around the robot to ensure a safe robot installation. Thefence must be dimensioned to withstand the force created if the load being handled bythe robot is dropped or released at maximum speed. The maximum speed is determinedfrom the maximum velocities of the robot axes and from the position at which the robotis working in the workcell (see Product Specification -Description, Robot Motion).

Applicable standards are ISO/DIS 11161 and prEN 999:1995.

1.12 Standards of interest when the robot is part of a cell

1.13 Risks Associated with Live Electric Parts

1.13.1 Controller

A danger of high voltage is associated with the following parts:

- The mains supply/mains switch- The power unit

- The power supply unit for the computer system (55VAC)

- The rectifier unit (260VAC and 370V DC. NB: Capacitors!)

EN 294 Safety of machinery - Safety distance to prevent danger zones being reached bythe upper limbs.

EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the humanbody.

EN 811 Safety of machinery - Safety distance to prevent danger zones being reached bythe lower limbs.

Pr EN 999 Safety of machinery - The positioning of protective equipment in respect ofapproach speeds of the human body.

EN 1088 Safety of machinery - Inter locking device associated with guards principles fordesign and selection.

Table 1 Standards of interest when the robot is part of a cell

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Safety Safety

1.13.2 Manipulator

A danger of high voltage is associated with the manipulator in:

- The power supply for the motors (up to 370V DC)

- The user connections for tools or other parts of the installation (max.230VAC, see Product Manual -Installation and Commissioning)

1.13.3 Tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in theOFF position. Power supply cables which are in motion during the working processmay be damaged.

1.14 Emergency Release of Mechanical Arm

If an emergency situation occurs where a person is trapped by the mechanical robotarm, the brake release buttons should be pressed whereby the arms can be moved torelease the person. To move the arms by manpower is normally possible on thesmaller robots (1400 and 2400), but for the bigger ones it may not be possible withouta mechanical lifting device such as an overhead crane.

If power is not available the brakes are applied and therefore manpower may not besufficient for any robot.

Before releasing the brakes, be sure that the weight of the arms does not enhancethe pressure on the trapped person.

1.15 Limitation of Liability

The above information regarding safety must not be construed as a warranty byABB Robotics that the industrial robot will not cause injury or damage even if all

safety instructions have been complied with.

1.16 Related Information

D ib d i

Safety Safety


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Safety Safety

To the User


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Wereserveallrightsinthis

documentandinthe

informationcontainedthere

in.

Reproduction,useor

disclosuretothirdpartiesw

ithoutexpressauthorityis

strictlyforbidden.A

BBR

oboticsProductsAB

Declaration by the manufacturer

as defined by machinery directive 89/392/EEC Annex II B

Herewith we declare that the industrial robot

IRB 140 IRB 340 IRB 640 IRB 1400 IRB 2400 IRB 4400

IRB 6400S IRB 6400PE IRB 6400R IRB 840

manufactured by ABB Robotics Products AB 721 68 Vsters, Sweden

with serial No.

Label withserial number

is intended to be incorporated into machinery or assembled with other machinery to constitute

machinery covered by this directive and must not be put into service until the machinery into

which it is to be incorporated has been declared in conformity with the provisions of the

directive, 91/368 EEC.

Applied harmonised standards in particular:

EN 292-1 Safety of machinery, basic terminology

EN 292-2 Safety of machinery, technical principles/specifications, emergency stop

EN 418 Safety of machinery, emergency stop equipment

EN 563 Safety of machinery, temperatures of surfaces

EN 614-1 Safety of machiney, ergonomic design principles

EN 775 Robot safety

EN 60204 Electrical equipment for industrial machines 1)

prEN 574 Safety of machinery, two-hand control device

prEN 953 Safety of machinery, fixed / moveable guards

prEN 954-1 Safety of machinery, safety related parts of the control system

EN 50081-2 EMC, Generic emission standard. Part 2: Industrial environment

EN 55011 Class A Radiated emission enclosure

EN 55011 Class A Conducted emission AC Mains

EN 50082-2 EMC, Generic immunity standard. Part 2: Industrial environmentEN 61000-4-2 Electrostatic discharge immunity test

EN 61000-4-3 Radiated, radio-frequency, electromagnetic field immunity yest

ENV 50204 Radeated electromagnetic field from digital radio telephones, immunity test

EN 61000-4-4 Electrical fast transient/burst immunity test

ENV 50141 Conducted disturbences induced by radio-frequency fields, immunity test

To the UserDeclaration by the manufacturer.This is only a translation of the customs declaration. The originaldocument (in English) with the serial number on it is suppliedtogether with the robot

ORINFOR

MATION

ABB ROBOTICS PRODUCTS AB CONFIGURATION LIST


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ABB ROBOTICS PRODUCTS AB CONFIGURATION LIST

Robot type: Revision: Manufact order no: Serial no:

For RAC: RAC Ref no: Sales order no:

Tested and approved: Date Name

MANIPULATOR:

CONTROL SYSTEM:

ROBOT SYSTEM:

DateDelivery from factory:

Delivery to customer:

Acceptance by customer:

Customer information:

Customer:

Address:

OPTIONS/DOCUMENTATION

QTY OPTION/PARTNO REVISION DESCRIPTION

To the User

The Configuration List is an individual specification of the robotsystem delivered regarding configuration and extent.

On delivery, the complete document is placed in the robot controller.


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page

General ................................................................................................... 1

Manipulators ................................................................................... 1

Controller ........................................................................................ 1

Scrapping................................................................................................. 2

General warning ............................................................................. 2

Oil and grease ................................................................................ 2

Parts requiring special treatment when scrapping ......................... 2

IRB 140, 1400, 2400 and 4400: Motors ......................................... 2

IRB 4400: Balancing cylinder ......................................................... 3

IRB 6000/6400/6400R and IRB 640: Balancing cylinder ................ 3

Scrapping Balancing cylinders ....................................................... 4
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The components of the robot are manufactured from many different materials. Someof them are listed below to facilitate scrapping, i.e. so that the components can bedisposed of in a way that does not have a detrimental effect on anyones health or theenvironment.

Lead Counter-weight IRB 6400

Batteries,NiCad or Lithium

Serial measurement board All robot types

Copper Cables, motors All robot types

Cast iron/nodular iron Base, lower arm, upper arm, parallel bar/arm

All robot types

Steel Gears, screws, base-frame, etc. All robot types

Samarium-Cobalt Brakes, motors IRB 1400, 2400, 4400

Neodymium Brakes, motors IRB 6400, 640

Plastic/rubber (PVC) Cables, connectors, drive belts, etc. All robot types

Oil, grease Gearboxes All robot types

Aluminium Covers, sync. brackets All robot types

Castings in wrist, upper arm tubular IRB 1400, 2400

Copper Transformers, cables

Tin Cables

Alu-Zinc sheeting Control cabinets, various sheet metal parts

I T f


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Where possible, arrange for the oil and grease to be recycled. Dispose of via anauthorised person/contractor in accordance with local regulations. Do not dispose ofoil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration may

be carried out under controlled conditions in accordance with local regulations.Also note that:

- Spills may form a film on water surfaces causing damage to organisms.Oxygen transfer could also be impaired.

- Spillage may penetrate the soil causing ground water contamination.

Special care is needed when removing certain parts from the robot, before scrappingthe part in question. The types of robot on which there are such parts are listed belowtogether with a description of how they should be removed.


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The balancing cylinder contains 3 preloaded spiral springs. Before scrapping (meltingdown, or other form of destruction) the springs must be unloaded in a safe way.

The balancing cylinder contains 12 preloaded spiral springs (see Figure 2). Beforescrapping (melting down, or other form of destruction) the springs must be unloadedin a safe way, (see section 1.2.7).

There are different types of balancing cylinder with a preloading force between 45008000 N.

The free length of the unloaded springs is about 300400 mm excluding the length ofthe balancing cylinder.

Spiral spring

L = 470 mm

Double Spiral spring
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The normal way to scrap the balancing cylinder is to use a so-called shredder orscrapping mill. All the balancing cylinders can be treated in this way.

All-enclosed scrapping mills in which the scrap is ground to chips, e.g or similar, are available at all major scrap merchants.

If a scrapping mill is not available, the balancing cylinder (except 3HAA 0001-EZ)

can be opened by means of a blowpipe as shown in the sketches (see Figure 3).

- Cut a hole (250 x 150 mm) in the mantel surface and then cut all theuncovered spring. Finally cut a hole (40 mm) in the piston rod, alt. A, or cutoff the piston rod end, alt. B (see Figure 4).

- Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncoveredspring so it will be possible to cut another hole (200 x 100 mm) in the innermantel surface. Cut the inner spring and cut off the piston rod end (seeFigure 3).

- This type of balancing cylinder has an outer jacket of aluminium, which

means it cannot be opened by means of a blowpipe. Furthermore, thealuminium must be separated from the steel before recycling and this can onlybe done in a shredder or by the manufacturer (see Figure 5).

ca. 250

ca. 200

Cut off Piston rod
http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/http://0.0.0.0/


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ca. 250

Hole in the Piston rodCut off Spiral spring

Alternative A

ca. 250

Cut off Spiral spring

Cut off Piston rod

Alternative B

Ca 40mm


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Description


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Contents page

1 Computer System 11.1 Interfaces of the computer system.................................................. 1

1.1.1 Main computer board........................................................... 1

1.1.2 Axis computer board............................................................ 1

1.1.3 I/O computer board.............................................................. 1

1.1.4 Optional boards ................................................................... 1

2 Servo System 3

2.1 Principle function............................................................................. 3

2.2 Regulation ....................................................................................... 3

2.3 Controlling the robot ........................................................................ 3

2.4 Motor Overload................................................................................ 4

3 I/O System 5

4 Safety System 7

4.1 The chain of operation..................................................................... 7

4.2 MOTORS ON and MOTORS OFF modes....................................... 8

4.3 Safety stop signals .......................................................................... 8

4.4 Limitation of velocity ........................................................................ 9

4.5 ENABLE .......................................................................................... 9

4.6 24V supervision............................................................................... 9

4.7 Monitoring........................................................................................ 9

5 External Axes 11

Description Contents


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page

Computer System


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1 Computer System

1.1 Interfaces of the computer system

The computer system is made up of three computers boards (see Figure 1). Thecomputer system comprises: Main Computer Board, Axis Computer Board, and I/OComputer Board.

The computers are the data processing centre of the robot. They possess all the

functions required to create, execute and store a robot program. They also containfunctions for coordinating and regulating the axis movements. Figure 1shows howthe computer system communicates with the other units.

In addition to these boards it is possible to add up to five Optional Boards foradditional functionality.

1.1.1 Main computer board

The Main Computer Board contains the main computerof the robot and controls theentire robot (Man-Machine Interface, execution of RAPID programs, path control ofthe robot).

1.1.2 Axis computer board

Regulates the speed and position of up to seven axes. Set points for positions are sent

from the main computer to the axis computer.The axis computer receives position set values from the main computer and currentposition from the serial measurement board. The axis computer uses this data inregulating algorithms and transmits the torque set value and the position values to thedrive system.

1.1.3 I/O computer board

This is the link between the main computer and the process equipment, e.g I/O units.

To find out where the various boards are located, see Chapter 9,Installation andCommissioning.

Computer System Computer System


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See also note1, note2and note3

Figure 1 The interfaces of the computer system.

Ethernet (LAN) Serial portsMC/CONSOLE1, COM12

USB

Flash disk

Floppy diskdrive (Option)

Cooling fansMain computer

SMBusBattery unit

Computer powersupply

Process powersupply

Axis computer

I/O computer

Optional board

(0-5)

Ethernet (Service)Enable 1

TPU

Panel unit

Test inputs

Drive system 1Measurement system 2

Drive system 2

Enable 2

PCI bus

Measurement system 1

I/O units (Optional)

See Figure 2

See Figure 3

See Figure 3

See Figure 3

I/O units (Optional)

Gateway units (Optional)

Field bus I/O (Optional

Serial channels COM23, COM33

CAN

CAN

Gateway units (Optional)

Servo System


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2 Servo System

2.1 Principle function

The servo system is a complex system comprising several different interacting unitsand system parts both hardware and software. The servo function comprises:

- Digital regulation of the position, velocity and motor current of the robot axes.

- Synchronous AC operation of the robot motors.

2.2 Regulation

During execution, new data on the position of the robot axes is continuously receivedfrom the serial measurement board. This data is received by the position regulator andcompared with previous position data. After it has been compared and amplified, newreferences are given for the position and velocity of the robot.

The system also contains a model of the robot which continuously calculates theoptimal regulator parameters regarding gravity, moment of inertia and interactionbetween axes. See Figure 2.

2.3 Controlling the robot

A digital current reference for two phases is calculated on the basis of the resolversignal and a known relationship between the resolver angle and rotor angle. The thirdphase is created from the other two.

The current of the three phases is regulated in the drive unit in separate currentregulators. In this way, three voltage references are returned which, by pulse-modulating the rectifier voltage, are amplified to the working voltage of the motors.

The serial measurement board receives resolver data from a maximum of six resolversand generates information on the position of the resolvers.

The following diagram (Figure 2) outlines the system structure for AC operation aswell as the fundamental structure of the drive unit.

Servo System Servo System


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Figure 2 System structure for AC operation.

2.4 Motor Overload

PTC resistance is built into the robot motors to provide thermal protection againstoverloads. The PTC sensors are connected to an resistance sensitive input on the panelunit which monitors that a low level of resistance is maintained.

The robot computer checks the motors for overloading at regular intervals by readingthe panel unit register. In the event of an overload, all the motors are switched off.

Computer

Serial measurementboard

DC Link Drive unit M R

Torquereference

Rotorposition

CurrentEstimator

M

M

M

U

W

V

M

DC Link

Drive System 1/2

Measurement System 1/2

PWM

PWM

PWM

PWM

Powercircuits

I/O System


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3 I/O System

Communicates with other equipment using digital and analog input and outputsignals.

Floppy disk

Flash disk

ATA / EIDE

USB

RS 232

COM1

1

Main Computer

I/O ComputerTPU

Ethernet (Service)

GeneralSerial ports

Gateway

unit

I/O unit (s)

Panel unit

RS 422

RS 232

COM32

COM22

I/O I/O I/O

16

16

CAN2

CAN1

PCI bus


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Safety System Safety System


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The safeguarded stop GENERAL STOP is active in all operating modes and isconnected by the user.

The aim of these safeguarded stop functions is to make the area around themanipulator safe while still being able to access it for maintenance and programming.

If any of the dual switches in the safety circuit are opened, the circuit breaks, themotor contactors drop out, and the robot is stopped by the brakes. If the safety circuitbreaks, an interrupt call is sent directly from the panel unit to the computer system toensure that the cause of the interrupt is indicated.

When the robot is stopped by a limit switch, it can be moved from this position byjogging it with the joystick while pressing the MOTORS ON button. The MOTORSON button is monitored and may be depressed for a maximum of 30 seconds.

LEDs for ES, AS and GS are connected to the two safety circuits to enable quicklocation of the position where the safety chain is opened. The LEDs are located on theupper part of the panel unit. Status indication is also available on the TPU display.

4.2 MOTORS ON and MOTORS OFF modes

The principle task of the safety circuit is to ensure that the robot goes into MOTORSOFF mode as soon as any part of the chain is opened. The computer system itselfcontrols the last switch.

In AUTO mode, you can switch the robot back on by pressing the MOTORS ONbutton on the operators panel. If the circuit is OK, the computer system will close theSolid state switch to complete the circuit.

When switching to MANUAL, the mode changes to MOTORS OFF and the computer

system opens the Solid state switch.

In any of the MANUAL modes, you can start operating again by pressing the enablingdevice on the Teach Pendant Unit. If the circuit is OK, the computer system will closethe Solid state switch to complete the circuit.

4.3 Safety stop signals

According to the safety standard ISO/DIS 11161 Industrial automation systems -safety of integrated manufacturing systems - Basic requirements, there are twocategories of safety stops, category 0 and category 1. A safety analysis will showwhether category 0 or 1 is applicable, see Table 1below.

All the robots safet stops are categor 0 stops as defa lt Safet stops of categor 1


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Safety System Safety System


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External Axes External Axes


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Installation and Commissioning Contents


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page

2.9 External safety relay.........................................................................232.10 Safeguarded space stop signals ......................................................24

2.10.1 Delayed safeguarded space stop .........................................24

2.11 Available voltage..............................................................................24

2.11.1 24V I/O supply ...................................................................... 24

2.11.2 115/230 VAC supply ............................................................. 25

2.12 External 24V supply .........................................................................252.13 Connection and address keying of the CAN-bus .............................26

2.13.1 CAN 1.1 - 1.3........................................................................26

2.13.2 CAN 2 ...................................................................................27

2.13.3 DeviceNet Connector ...........................................................28

2.13.4 ID setting ..............................................................................28

2.14 Distributed I/O units..........................................................................29

2.14.1 General.................................................................................29

2.14.2 Sensors ................................................................................29

2.14.3 Digital I/O DSQC 328 (optional)............................................30

2.14.4 AD Combi I/O DSQC 327 (optional) .....................................32

2.14.5 Analog I/O DSQC 355 (optional) .......................................... 34

2.14.6 Encoder interface unit DSQC 354 ........................................38

2.14.7 Relay I/O DSQC 332 ............................................................ 40

2.15 Digital 120 VAC I/O DSQC 320........................................................42

2.16 Field bus, master/slave ....................................................................45

2.16.1 Profibus-DP m/s DSQC 510 .................................................45

2.16.2 Examples of how to connect Profibus to the robot system...472.17 Gateway (Field bus) units ................................................................48

2.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLCDSQC 350 ............................................................................48

2 17 2 Interbus S slave DSQC 351 50

Contents Installation and Commissioning


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page

3.1.2 Installation of the RobotWare on the PC.............................. 633.1.3 Additional content on the RobotWare CD-ROM .................. 63

3.1.4 The manipulator parameter disk: ......................................... 63

3.2 Installing new Robot Controller Software with RobInstall................ 64

3.2.1 How to use RobInstall .......................................................... 64

3.3 Create a new Robot Controller System........................................... 65

3.3.1 Setting up the system .......................................................... 653.3.2 Add or remove external options........................................... 66

3.3.3 Add or remove additional system parameters ..................... 66

3.3.4 Change options or system pack revision ............................. 66

3.4 Update the Robot Controller image................................................. 67

3.5 Transfer Robot Controller System using Ethernet connection ........ 68

3.5.1 Set up before downloading a Robot Controller System....... 68

3.5.2 Download Robot Controller System..................................... 69

3.6 Transfer Robot Controller System using floppy disks...................... 70

3.6.1 Set up before Robot Controller System transfer.................. 70

3.6.2 Create Boot Diskettes from RobInstall................................. 70

3.7 RobInstall preferences .................................................................... 71

4 Robot Controller 73

4.1 BootImage....................................................................................... 73

4.2 Start window.................................................................................... 73

4.3 Reboot............................................................................................. 73

4.4 Boot Disks ....................................................................................... 74

4.5 Network Settings ............................................................................. 74

4.5.1 LAN Settings........................................................................ 74

4.5.2 Service Settings................................................................... 75

4 6 Select System 76

Installation and Commissioning Contents


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page

5 Calibration 81

5.1 Updating the revolution counter .......................................................81

5.2 How to use the disk, Manipulator Parameters .................................81

5.2.1 Robot delivered with controller software installed................. 81

5.2.2 New controller software installed with RobInstall..................81

6 System directory structure 83

6.1 Media Pool in the PC .......................................................................83

6.1.1 Media Pool directory.............................................................83

6.2 System Pool in the PC .....................................................................83

6.2.1 System Pool directory...........................................................84

6.2.2 Preparation of S4Cplus software to be installed...................84

6.3 File structure in the robot controller mass storage memory.............85

6.3.1 Check Storage Capacity .......................................................85

6.3.2 Increase Storage Capacity ...................................................86

Installation and Commissioning

1 On Site Installation


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1 On-Site Installation

1.1 Transporting and Unpacking

Before starting to unpack and install the robot system, read the safety regulationsand other instructions very carefully. These are found in separate sections in theUsers Guide and Product manual.

The installation must be done by qualified installation personnel and should con-

form to all national and local codes.

When you have unpacked the cabinet, check that it has not been damaged duringtransport or while unpacking.

Operating conditions:

Ambient temperature + 5C to + 45C (direct air cooling)

Ambient temperature + 5C to + 52C (Peltier cooling)

Relative humidity Max. 95% at constant temperature

Storage conditions:

If the equipment is not going to be installed straight away, it must be stored in a dryarea with an ambient temperature between -25C and +55C.

The net weight of the cabinet is approximately: 240 kg

1.2 System CD ROM and diskette

The System CD ROM and the Manipulator parameter disk are delivered with therobot system (see section 3.1.1).

Installation and Commissioning On-Site Installation


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1.3 Lifting the Cabinet

Use the four lifting devices on the cabinet or a fork lift when lifting the controller,(see Figure 1).

Figure 1 The maximum angle between the lifting straps when lifting the controller.

If the controller is supplied without its top cover, lifting devices must not be used.

Instead, use a fork lift truck.

A

A

A - A

Min. 60

On-Site Installation Installation and Commissioning


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1.4 Amount of space required

200

950

980 *

500

500

820

Lifting points* Castor wheels, Option 126

800

250

Extended cover

Option 123

Cabinet extension

Option 124

for forklift

200

Air distance to wall

800

70



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1.5 Bolting the cabinet

The cabinet may be secured to the floor using M10 screws (see Figure 3).

Figure 3 Footprint drawing

1.6 Connecting the manipulator to the controller

Two cables are used to connect the controller to the manipulator, one for measuringsignals and the other for motor and brakes.

The connections on the manipulator are located on the rear of the robot base.

1.6.1 Connection on left-hand side of cabinet

The cables are connected to the left side of the cabinet using an industrial connectorand a Burndy connector (see Figure 4).

Figure 4 Connections on the cabinet wall.

400

720

XS2

XS1

Motor cable XP1

Measurementcable XP2


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Cable connectors are supplied (option 132 - 134).


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pp p

Figure 6 Mains connection via an optional wall socket.

1.8 Inspection before start-up

Note! Keep the front door and the top lid closed to prevent the intrusion of dirt and dust.Before power on, check that the following have been performed:

1. The controller mains section is protected with fuses.

2. The electrical connections are correct and correspond to the identification plate onthe controller.

3. The teach pendant and peripheral equipment are properly connected.

4. That limiting devices that establish the restricted space (when utilised) areinstalled.

5. The physical environment is as specified.

6. The operating mode selector on the operators panel is in the Manual modeposition.

When external safety devices are used, check that these have been connected or thatthe following circuits in either XS3(connector on the outside left cabinet wall) or X1-X4(screw terminals on the panel unit) are strapped.

XS3 Panel unit

External limit switches A5-A6, B5-B6 X1.3-4, X2.3-4

External emergency stop A3-A4, B3-B4 X1.9-10, X2.9-10

External emergency stop internal 24 V, A1-A2, B1-B2 X1.7-8, X2.7-8

General stop + A11-A12, B11-B12 X3.10-12, X4.10-12

General stop A13 A14 B13 B14 X3 7 8 X4 7 8

CEE connector DIN connector

On-Site Installation Installation and Commissioning

1 9 St t


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1.9 Start-up

1.9.1 General

1. Switch on the mains switch on the cabinet.

2. The robot performs its self-test on both the hardware and software. This test takesapproximately 1 minute.

If the robot is supplied with software already installed, proceed to pos. 3 below.

Otherwise continue as follows (no software installed):3. Install the software as described in chapter 3.

4. A welcome message is shown on the Teach Pendant Unit display.

5. To switch from MOTORS OFF to MOTORS ON, press the enabling device on theteach pendant.

6. Update the revolution counters as described in chapter 15:Repairs, Calibration.

7. Check the calibration position as described in chapter 15:Repairs, Calibration.

8. When the controller, with the manipulator electrically connected, is powered up forthe first time, ensure that the power supply is connected for at least 36 hourscontinuously, in order to fully charge the batteries for the serial measurementboard. It takes approx. 4 hours to fully charge a computer system battery.

9. After having checked the above, verify that

- the start, stop and mode selection (including the key lock switches) control deviceswork as intended.

- each axis moves and is restricted as intended.

- emergency stop and safety stop (where included) circuits and devices are func-tional.

- it is possible to disconnect and isolate the external power sources.

- the teach and playback facilities work correctly.

- the safeguarding is in place.- at reduced speed, the robot operates properly and has the capability to handle the

product or workpiece.

- in automatic (normal) operation, the robot operates properly and has the capabilityf h i d d k h d d d l d



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Installation and Commissioning Connecting Signals

2 3 Interference elimination


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2.3 Interference elimination

Internal relay coils and other units that can generate interference inside the controllerare neutralised. External relay coils, solenoids, and other units must be clamped in asimilar way. Figure 7illustrates how this can be done.

Note that the turn-off time for DC relays increases after neutralisation, especially if adiode is connected across the coil. Varistors give shorter turn-off times. Neutralisingthe coils lengthens the life of the switches that control them.

Figure 7 Examples of clamping circuits to suppress voltage transients.

2.4 Connection types

I/O, external emergency stops, safety stops, etc., can be supplied on screw connectionsor as industrial connectors.

Designation

X(T) Screw terminal

XP Pin (male)

+24V DC +0V

+24V DC, or AC voltage +0V

The diode should be dimensioned for thesame current as the relay coil, and a voltage of twice the supply voltage.

The varistor should be dimensioned for thesame energy as the relay coil, and a voltageof twice the supply voltage.

R 100 ohm, 1WC 0.1 - 1 mF> 500 V max. voltage125 V nominal voltage

R C

Connecting Signals Installation and Commissioning

2 5 Connections


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2.5 Connections

Detailed information about connection locations and functions will be found inchapter 12, Circuit Diagram.

2.5.1 Shield grounding

To avoid getting distortions into the robot controller that can interrupt the functionalityof the controller, it is very important that the shield of the cable is grounded to the

controllers wall. The grounding of the shield must be made there the cable is enteringthe controller. The cable must go through a cable gland on the controller wall wherethe cable shield must be connected to the cable gland. The cable gland must in turn beconnected to the controllers wall with screws with scratches to get a good groundingbetween the cable gland and the robot controllers wall.

2.5.2 To screw terminal

Panel unit and I/O units are provided with keyed screw terminals for cables with anarea between 0.25 and 1.5 mm2. A maximum of two cables may be used in any oneconnection.

Note! The cable shield must be connected to the cabinet wall using EMC connectingcable glands. The shield must continue right up to the screw terminal.

The installation should comply with the IP54 (NEMA 12) protective standard.

Bend unused conductors backwards and attach them to the cable using a clasp, orsimilar. To prevent interference, ensure that such conductors are not connected at theother end of the cable (antenna effect). In environments with much interference,disconnected conductors should be grounded (0V) at both ends.

2.5.3 To connectors (option)

Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652)

can be found on the left-hand side or front of the cabinet (depending on the customer


order) See Figure 8and Figure 5.


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Figure 8 Positions for connections on the left-hand side of the controller.

In each industrial connector there is space for four rows of 16 conductors with amaximum conductor area of 1.5 mm2. The pull-relief clamp must be used whenconnecting the shield to the case.

The manipulator arm is equipped with round Burndy/Framatome connectors(customer connector not included).

Bend unused conductors backwards and attach them to the cable using a clasp, orsimilar. To prevent interference, ensure that such conductors are not connected at theother end of the cable (antenna effect). In environments with much interference,disconnected conductors should be grounded (0V) at both ends.

When contact crimping industrial connectors, the following applies:

1. Using a special crimp tool, crimp a pin or socket on to each non-insulatedconductor

Operators panel

in separate cabinetExternal axes Safety signals

External conn. Device Net

Mains conn.

I/O connections

External axes inRobot cabinet

ApplicationInterface Manipulator cables

EquipmentPosition switchesconnection to cabinet


2.6 Connection to screw terminal


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2.6 Connection to screw terminal

Sockets with screwed connections for customer I/O, external safety circuits, customersockets on the robot, external supply to electronics. See also note1.

Locations of socket terminals are shown in Figure 9. See also circuit diagram, Viewof control cabinet, for more details.

Signal identification Location Terminals

Safeguarded stop Panel unit X1 - X4

Digital I/O I/O unit X1 - X4

Combi I/O I/O unit X1 - X4, X6

Relay I/O I/O unit X1 - X4

RIO I/O I/O unit X1, X2

COM21, COM31 Base Connector Unit X10, X9

CAN 1.1 (internal unit) Base Connector Unit X15

CAN 1.2 (manipulator, I/O units) Base Connector Unit X6

CAN 1.3 (external I/O units) Base Connector Unit X7

CAN 2 (external I/O units) Base Connector Unit X824V supply (2A fuse) XT31

115/230V AC supply XT21

Table 3 Connections to screw terminal


X7 (CAN 1.3) X8 (CAN 2)X6 (CAN 1.2)


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Cabinet view from above

X9 (COM31)

X15 (CAN1.1)

Computer system

Base Connector Unit

I/O Units (X4)

X 1 - X 4Safety Signals

X10 (COM21)

XT 31(24V I/O)

(COM11)

Panel Unit

Manipulator connections115/230 VAC


2.7 The MOTORS ON / MOTORS OFF circuit


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To set the robot to MOTORS ON mode, two identical chains of switches must beclosed. If any switch is open, the robot will switch to MOTORS OFF mode. As longas the two chains are not identical, the robot will remain in MOTORS OFF mode.Figure 10shows an outline principle diagram of the available customer connections,AS, GS and ES.

Figure 10 MOTORS ON /MOTORS OFF circuit.

AS

Automatic mode

Solid State Switches Contactor

Operating mode selector

ED = TPU Enabling Device

AS = Automatic mode safeguarded space stop

LS = Limit Switch

ES = Emergency Stop

EN1

GS = General mode safeguarded space stop

MEN2RUN

2:ndchain

interlock

Driveunit

&

GS

ED

LS

Manual mode

Computer commands

Mains

ES


2.7.1 Connection of safety chainsExt LIM1 K11


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Figure 11 Diagram showing the two-channel safety chain, see also note1.

Technical data per chain

Limit switch: loadmax. V drop

300 mA1V

External contactors: load 10 mA

Man1Auto1

Man2Auto2

X1:11

X3:10

X2:11

X4:10

X4:3

X3:3

X3:71

9

12

11

8

4

4

9

11

8

12

Ext LIM2

External contactors

Ext LIM1

GS1

AS1

TPU En1

ES1

Optoisol.

Optoisol.

& EN

RUN Inter-

locking

K1

K2

K1

0 V

K2

M

Drive unit

AS2

GS2

ES2

TPU En2 &

24V1

See 2.7.2

Opto

isol.

Opto

isol.

24 V

24 V

CONT1

CONT2

24V

X4:7

0V

+

+

-

-

0 V

0 V

+

+

-

-

X3:12X4:12

See 2.7.2


2.7.2 Connection of ES1/ES2 on panel unitInternal


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24V 0V

X1:4 X1:3X1:7

X1:9X1:10

TPU Cabinet

X1:1

X1:2

X1:6

24V

ES1 Internal

24V

Run Chain 1 top

X1:4

X1:5

Internal

24V 0V

X2:4 X2:3

X2:7X2:9X2:10

TPU Cabinet

X2:1

X2:2

X2:6

24V

ES2 Internal

24V

Internal

X1:8

X2:8

Ext. stop

Ext. stop


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2.8 External customer connections on panel unit X1X4


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Figure 16 Customer connections: X1X4, located on the panel unit.

2.8.1 X1; 12-pole type Phoenix COMBICON connector

See also note1.

Signal

1

Terminal no: CommentES1 out:A 1 Emergency stop out chain 1

ES1 out:B 2 Emergency stop out chain 1

ES1 top 3 Top of emergency stop chain 1

24Vpanel 4 +24V emergency stop chain 1 and run chain 1

Run Ch1 top 5 Top of run chain 1

ES1 internal 6 Internal signal from emergency stop relay chain 1

Sep. ES1:A 7 Separated emergency stop chain 1

Sep. ES1:B 8 Separated emergency stop chain 1

ES1 bottom 9 Bottom of emergency stop chain 1

0V 10 0V emergency stop chain 1

AS2AS1GS1ES2ES1 GS2NSMSEN

WARNING!REMOVE JUMPERS BEFORE CONNECTING

ANY EXTERNAL EQUIPMENT

X1

X2

X3

X4

Chain statusLEDs

1 2 4 53 6 7 8 9 10 1211

1 2 4 53 6 7 8 9 10 1211 1 2 4 53 6 7 8 9 10 1211

1 2 4 53 6 7 8 9 10 1211

= jumper


2.8.2 X2, 12-pole type Phoenix COMBICON connector

See also note1


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See also note .

2.8.3 X3; 12-pole type Phoenix COMBICON connector.

Signal1 Terminal no: Comment

ES2 out:A 1 Emergency stop out chain 2

ES2 out:B 2 Emergency stop out chain 2

ES2 top 3 Top of emergency stop chain 2

0V 4 0V emergency stop chain 2 and run chain 2

Run Ch2 top 5 Top of run chain 2ES2 internal 6 Internal signal from emergency stop relay chain 2

Sep. ES2:A 7 Separated emergency stop chain 2

Sep. ES2:B 8 Separated emergency stop chain 2

ES2 bottom 9 Bottom of emergency stop chain 2

24Vpanel 10 24V emergency stop chain 2

Ext. LIM2:A 11 External limit switch chain 2

Ext. LIM2:B 12 External limit switch chain 2

Table 10 Signal descriptions for X2

Signal1 Terminal no: Comment

Ext. MON 1:A 1 Motor contactor 1

Ext. MON 1:B 2 Motor contactor 1

0V 3 External contactor 1 0V

CONT1 4 External contactor 1

5 No connect

6 No connect

0V 7 0V to auto stop and general stop

GS1 - 8 General stop minus chain 1

AS1 - 9 Auto stop minus chain 1

GS1 + 10 General stop plus chain 1

AS1 11 A l h i 1


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2.10 Safeguarded space stop signals


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According to the safety standard ISO/DIS 11161 Industrial automation systems -safety of integrated manufacturing systems - Basic requirements, there are twocategories of safety stops, category 0 and category 1. A safety analysis will show ifcategory 0 or 1 is applicable, see Table 13below.

2.10.1 Delayed safeguarded space stop

All the robots safety stops are as default category 0 stops.Safety stops of category 1 can be obtained by activating the delayed safeguardedspace stop together with AS or GS. A delayed stop gives a smooth stop. The robotstops in the same way as a normal program stop with no deviation from theprogrammed path. After approx. 1 second the power supply to the motors is shut off.The function is activated by setting a parameter, see Users Guide - SystemParameters, Topic: I/O Signals.

2.11 Available voltage

2.11.1 24V I/O supply

The robot has a 24V supply available for external and internal use.

The 24V I/O is not galvanically separated from the rest of the controller voltages.

Technical data

Voltage 24.0 - 26.4VRipple Max. 0.2V

Category 0 Category 1

The category 0 stop is to be used when the powersupply to the motors must be switched off imme-

diately, such as when a light curtain, used to pro-tect against entry into the work cell, is passed.This uncontrolled motion stop may require spe-cial restart routines if the programmed pathchanges as a result of the stop.

Category 1 is preferred if it is acceptable, such aswhen gates are used to protect against entry into

the work cell. This controlled motion stop takesplace within the programmed path, which makesrestarting easier.

Table 13 Description of safety categories


2.11.2 115/230 VAC supply

The robot has an AC supply available for external and internal use.


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pp y

This voltage is used in the robot for supplying optional service outlets.

The AC supply is not galvanically separated from the rest of the controller voltages.

Technical data

Voltage 115 or 230VPermitted customer load Max. 500VAFuse size 3.15A (230V), 6.3A (115V)

AC supply is available for customer connections at XT 21 see Figure 9.

XT.21.1-5 230V (3.15A)XT.21.6-8 115V (6.3A)XT.21.9-13N (connected to cabinet structure)

2.12 External 24V supply

An external supply must be used in the following cases:

- When the internal supply is insufficient

- When the emergency stop circuits must be independent of whether or not the robothas power on, for example.

- When there is a risk that major interference can be carried over into the internal24V supply

An external supply is recommended to make use of the advantages offered by thegalvanic insulation on the I/O units or on the panel unit.

The neutral wire in the external supply must be connected in such a way as to preventthe maximum permitted potential difference in the chassis earth being exceeded. Forexample, a neutral wire can be connected to the chassis earth of the controller, or someother common earthing point.

Technical data:

Potential difference to chassis earth: Max. 60V continuousMax. 500V for 1 minute

Permitted supply voltage: I/O units 1935V including ripplepanel unit 20 630V including ripple


2.13 Connection and address keying of the CAN-bus


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2.13.1 CAN 1.1 - 1.3.

X15 CAN1.1 (Internal I/O) No termination of

the last unit

X7 CAN1.3

X6 CAN1.2

Base connector unit

I/O I/O I/O

I/O

I/O

I/O I/O

I/O

I/OSee Figure 22.

CAN bus

Control cabinet

Termination of


- CAN 1.1 is used for internal I/O unit mounted inside the cabinet. No terminatingresistor is to be mounted on CAN 1.1 regardless of whether there are any I/O unitsmounted or not. CAN 1.1 is connected to socket X15 on the Base connector unit


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(see 2.6).

- If CAN 1.2 is unused there should be a terminating resistor mounted in the X6socket (exceptional case see below).

- If CAN 1.2 is used, the terminating resistor should be moved to the last I/O uniton the CAN 1.2 chain.

- If CAN 1.3 is unused there should be a terminating resistor mounted in the X7socket (exceptional case see below).

- If CAN 1.3 is used, the terminating resistor should be moved to the last I/O uniton the CAN 1.3 chain.

Note! If CAN 1.2, for example, is not connected in the end of any CAN chain but some-where between the end points of the chain, then no terminating resistor should bemounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chainshould be terminated in both end points.

2.13.2 CAN 2

Figure 19 CAN 2

24 CA i i i

I/OI/OI/O

Base connector unit

1. 0V_CAN2. CAN_L3. drain

4. CAN_H5. 24V_I/O

X8 1. 0V_CAN2. CAN_L3. drain

4. CAN_H5. 24V_I/O

1.2.3.

4.5.

Termination oflast unit

120 W, 1%0.25 W Metal film

Controller

X8 CAN 2

See Figure 20



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Figure 20 CAN connections on base connector unit.

2.13.3 DeviceNet Connector

X5

Input and ID Signal name Pin Description

V- 0V 1 Supply voltage GND

CAN_L 2 CAN signal low

DRAIN 3 ShieldCAN_H 4 CAN signal high

V+ 5 Supply voltage 24VDC

GND 6 Logic GND

MAC ID 0 7 Board ID bit 0 (LSB)

MAC ID 1 8 Board ID bit 1




MAC ID 5 12 Board ID bit 5 (MSB)

T bl 14 Si l d i i f X5

X15 CAN 1.1 (Internal I/O)

X6 CAN 1.2 (External I/O)

X7 CAN 1.3 (External I/O)

X8 CAN 2 (External I/O)

1

12


6 8 9 10 11 127

(0V)

1 2 3 4 5


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Figure 21 Examples of address keying.

2.14 Distributed I/O units

2.14.1 General

Up to 201units can be connected to the same controller but only four of these can beinstalled inside the controller. Normally a distributed I/O unit is placed outside thecontroller. The maximum total length of the distributed I/O cable is 100 m (from oneend of the chain to the other end). The controller can be one of the end points or beplaced somewhere in the middle of the chain. For setup parameters, see Users Guide,section System Parameters, Topic: I/O Signals.

2.14.2 Sensors

S t d t ti l di it l it

X5 connec-tor

address pins

address key

1 48

16322

Example:

To obtain address 10:cut off address pins 2 and 8, see figure.

To obtain address 25:cut off address pins 1, 8 and 16.


The following sensors can be connected:

Sensor type Signal level

Di it l bit Hi h 1


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2.14.3 Digital I/O DSQC 328 (optional)

The digital I/O unit has 16 inputs and outputs divided up into groups of eight. Allgroups are galvanically isolated and may be supplied from the cabinet 24V I/O supplyor from a separate supply.

Technical data

See Product Specification for controller S4Cplus.

Further information

For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. ForCircuit diagram, see Chapter 12.

Connection table

Customer connections X1X4

Digital one bit sensors High 1

Low 0

Digital two bit sensors High 01

No signal 00

Low 10

Error status 11(stop program running)

Table 15 Sensors

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

101101

101 101

Status LEDs


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2.14.4 AD Combi I/O DSQC 327 (optional)

The combi I/O unit has 16 digital inputs divided into groups of 8, and 16 digital

outputs divided into two groups of 8 All groups are galvanically isolated and may be


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outputs divided into two groups of 8. All groups are galvanically isolated and may besupplied from the cabinet 24 V I/O supply or from a separate supply.

The two analog outputs belong to a common group which is galvanically isolatedfrom the electronics of the controller. The supply to the two analog outputs isgenerated from24 V_CAN (with galvanically isolated DC/AC converter).

Technical data


Further information

For setup parameters, see Users Guide - System Parameters, Topic: I/O Signals. ForCircuit diagram, see chapter 12.

Connection Table

Customer connections X1X4, X6.

Figure 23 AD Combi I/O DSQC 327

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

X6

1 10 101

1 6101 101

Status LEDs

X5

112

CAN-connection, see 2.13


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Connector X6

X6

Signal name Pin Explanation


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Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connectedto ground, to prevent disturbances, causes a short rush of current when setting theinput. When connecting outputs, sensitive to pre-oscillation current, a series resis-tor (100 ) may be used.

2.14.5 Analog I/O DSQC 355 (optional)

The analog I/O unit provides the following connections:

4 analog inputs, -10/+10V, which may be used for analog sensors etc.

4 analog outputs, 3 for -10/+10V and 1 for 4-20mA, for control of analog functionssuch as controlling gluing equipment etc.

24V to supply external equipment with return signals to DSQC 355.

Technical data


Further information

For setup parameters, see Users Guide -System Parameters, Topic: I/O Signals. ForCircuit diagram, see chapter 12.

S g p

AN_ICH1 1 For test purpose only

AN_ICH2 2 For test purpose only

0V 3 0V for In 1-2

0VA 4 0V for Out 1-2

AN_OCH1 5 Out ch 1

AN_OCH2 6 Out ch 2

Table 20 Connection table, X6


Connection table

Customer connections: X1, X3, X5X8

X8-Analog inputs X7-Analog outputs


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Figure 24 Analog I/O unit

Connector X5 DeviceNet connectors.

See section 2.13.3.

DSQC 355 ABB flexible Automation

Bus status LEDs

Analog I/O

X8

S3S2

X3X5

X2

X7

g p g p

X5-DeviceNet input Not to be usedand ID connector


Connector X7 - Analog outputs.

X7

Signal name Pin Description


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Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connectedto ground, to prevent disturbances, causes a short rush of current when setting theinput. When connecting outputs, sensitive to pre-oscillation current, a series resis-tor (100 ) may be used

ANOUT_ 1 Analog output 1, -10/+10



ANOUT_ 4 Analog output 4, 4-20mA

Not to be used 5

Not to be used 6Not to be used 7

Not to be used 8

Not to be used 9

Not to be used 10

Not to be used 11

Not to be used 12

Not to be used 13

Not to be used 14

Not to be used 15

Not to be used 16

Not to be used 17

Not to be used 18

GND 19 Analog output 1, 0VGND 20 Analog output 2, 0V

GND 21 Analog output 3, 0V

GND 22 Analog output 4, 0V

GND 23

GND 24

Table 21 Connection table, X7

1

12

13

24

Conn

s4cplus-product manual irb 6400r m2000_rev02

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