140 M2000

Product Manual IRB 140 3HAC 7564-1 / M2000

ABB Flexible Automation



Introduction CONTENTS Page 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.................................................................................................... 6 1.4.1 Manipulator...................................................................................... 6 1.4.2 Controller ......................................................................................... 10 1.4.3 Electronics unit ................................................................................ 10

Product Manual

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Product Manual IRB 140

Introduction 1 Introduction 1.1 How to use this Manual 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 both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance training course offered by ABB Flexible Automation. Anyone reading this manual should also have access to the User’s Guide. The chapter entitled System Description provides general information on the robot 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 chapter on Installation and Commissioning. If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults. Servicing and maintenance routines are described in the chapter on Maintenance.

1.2 What you must know before you use the Robot Normal maintenance and repair work Usually requires only standard tools. Some repairs, however, require specific tools. These repairs and the type of tool required, are described in more detail in the chapter Repairs. The power supply Must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orange-coloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller. Circuit boards - printed boards and components Must never be handled without Electro-Static Discharge (ESD) protection in order not to damage them. Use the wrist strap located on the inside of the controller door.

All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone. Product Manual

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Introduction

1.3 Identification Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2). The BaseWare O.S diskettes are also marked with the serial number (see Figure 3). Note! The identification plates and label shown in the figures below, only serve as examples. For exact identification see the plates on the robot in question.

ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Type:

IRB 6400R M2000

Robot version:

IRB 6400R/2.5-150

Man. order:

XXXXXX

Nom. load

See instructions

Serial. No:

6400R-XXXX

Date of manufacturing: Net weight 2,5.120 : 2060 kg 2.5-150 : 2060 kg 2,5-200 : 2230 kg

IRB 140(0)

IRB 640

4

IRB 2400

IRB 340

Identification plate showin the IRB 6400R / M2000

2000-XX-XX 2,8-150 : 2240 kg 2,8-200 : 2390 kg 3.0-100 : 2250 kg

IRB 4400

IRB 140

IRB 6400R

IRB 840/A

Figure 1 Examples of identification plate and its location on different manipulator types.

Product Manual

Introduction . ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden

Type: Robo t versi on: Volta ge: 3 x 400 V Powe

IRB 640 0R M9 9 IRB 640 0R/ 2.5150

Figure 2 Identification plate on the controller.

64-00000 System Key S4C 3.1 Program No 3 HAB2390-1/ Property of ABB Västerås/ Sweden. All rights reserved. Reproduction, modification, ABB Robotics Products AB Figure 3 Example of a label on a BaseWare O.S diskette.

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Introduction 1.4 Structure Manipulator The robot is made up of two main parts, the manipulator and controller. The controller is described in section 1.5. The Manipulator is equipped with maintenance-free AC motors, which have electromechanical brakes. The brakes lock the motors when the robot is inoperative for more than 1000 hours. The time can be configured by the user. The following figures show the various ways in which the different manipulators move and their component parts. Motor axis 5 Motor axis 6

Axis 3 Axis 4

Axis 5 Axis 6

Motor axis 4

Upper arm

Lower arm

Axis 2 Motor axis 1

Motor axis 2

Motor axis 3 Axis 1

Base Figure 4 The motion patterns of the IRB 1400 and IRB 140.

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Introduction

Motor unit axis 4 Motor unit axis 5 Motor unit axis 6

Upper arm Axis 4 Axis 3

Axis 6 Axis 5 Motor unit and gearbox axis 1

Lower arm Axis 2 Motor unit and gearbox axis 2

Motor unit and gearbox axis 3 Axis 1

Base Figure 5 The motion patterns of the IRB 2400.

Axis 5

Upper arm

Axis 4

Motor axis 4 Motor axis 5 Motor axis 6

Axis 6 Axis 3

Lower arm Axis Motor axis Motor axis Axis 1

Motor axis Base

Figure 6 The motion patterns of the IRB 4400

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Introduction

Upper arm

Axis 3

Axis4

Motor axis 4

Motor axis 5 Axis 5 Motor axis 6 Axis 6

Axis 2 Motor axis 1 Motor axis 2 Motor axis 3

Axis 1

Lower arm

Base Figure 7 The motion patterns of the IRB 6400R M99.

Axis 3

Upper arm

Motor axis 6

Axis 6 Axis 2 Motor axis 2 Motor axis 3 Lower arm Motor axis 1

Axis 1

Figure 8 The motion patterns of the IRB 640.

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Introduction

Motor 1(X)-axis

Motor 3(Z)-axis

Motor 2(Y)-axis Motor 4(C)-axis 2(Y)-axis

3(Z)-axis 4(C)-axis 1(X)-axis

Figure 9 The motion patterns of the IRB 840/A

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Introduction . Axis 2 Axis 3

Axis 2

Upper arm (x3)

Y Axis 3

Base box

Motors encapsulated

Bars (x3)

Axis 1 Axis 4, telescopic shaft (option)

Swivel X

Z Figure 10 The motion patterns of the IRB 340.

Motor axis 4 Motor axis 5 Motor axis 6

Axis 3 Axis 4

Lower arm

Upper arm Axis 5

Axis 2 Axis 6

Motor axis 1 Motor axis 3

Motor axis 2 Axis 1 Base Figure 11 The motion patterns of the IRB 140.

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Product Manual

Product Specification S4Cplus 3HAC 9039-1 / M2000 BaseWare OS 4.0

ABB Flexible Automation

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics AB. ABB Robotics AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics AB at its then current charge.

© ABB Robotics AB Article number: 3HAC 9039-1 Issue: M2000/BaseWare OS 4.0 ABB Robotics AB S-721 68 Västerås Sweden

Product Specification S4Cplus CONTENTS Page 1 Description ....................................................................................................................... 3 1.1 Structure.................................................................................................................. 3 1.2 Safety/Standards ..................................................................................................... 5 1.3 Operation ................................................................................................................ 7 Operator’s panel ..................................................................................................... 9 1.4 Memory .................................................................................................................. 11 Available memory .................................................................................................. 11 1.5 Installation .............................................................................................................. 12 Operating requirements.......................................................................................... 12 Power supply.......................................................................................................... 12 Configuration ......................................................................................................... 13 1.6 Programming .......................................................................................................... 13 Movements............................................................................................................. 14 Program management ............................................................................................ 14 Editing programs.................................................................................................... 14 Testing programs.................................................................................................... 15 1.7 Automatic Operation .............................................................................................. 15 1.8 The Rapid Language and Environment .................................................................. 16 1.9 Exception handling ................................................................................................. 16 1.10 Maintenance and Troubleshooting ....................................................................... 17 1.11 Robot Motion........................................................................................................ 17 Motion concepts..................................................................................................... 17 Coordinate systems ................................................................................................ 18 Stationary TCP....................................................................................................... 19 Program execution ................................................................................................. 19 Jogging ................................................................................................................... 19 Singularity handling............................................................................................... 20 Motion Supervision................................................................................................ 20 External axes .......................................................................................................... 20 Big Inertia .............................................................................................................. 20 Soft Servo............................................................................................................... 20 1.12 External Axes ....................................................................................................... 20 1.13 Inputs and Outputs................................................................................................ 22 Types of connection ............................................................................................... 23 I/O units (node types)............................................................................................. 23 Distributed I/O ....................................................................................................... 24 Signal data.............................................................................................................. 24 Product Specification S4Cplus M2000/BaseWare OS 4.0

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Product Specification S4Cplus System signals........................................................................................................ 1.14 Communication .................................................................................................... 2 Specification of Variants and Options........................................................................... 3 Index.................................................................................................................................

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Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1 Description 1.1 Structure The controller contains the electronics required to control the manipulator, external axes and peripheral equipment. The controller also contains the system software, i.e. the BaseWare OS (operating system), which includes all basic functions for operation and programming. Controller weight

250 kg

Controller volume:

950 x 800 x 620 mm

Airborne noise level: The sound pressure level outside the working space

< 70 dB (A) Leq (acc. to Machinery directive 98/37/EEC)

Teach pendant

Operator´s panel

Mains switch

Disk drive

Figure 1 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.

Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description

Air distance to wall

200

200

800

Cabinet extension 800

Option 124

820 Extended cover

500

Option 123 250

950 980 *

Lifting points for forklift

500

* Castor wheels, Option 126 71

52 623

Figure 2 View of the controller from the front, from above and from the side (dimensions in mm).

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Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.06/1999 Industrial robots, safety requirements ISO 9409-1 Manipulating industrial robots, mechanical interface ISO 9787 Manipulating industrial robots, coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC, Generic emission EN 50082-2 EMC, Generic immunity ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General Safety Requirements The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. The robot controller is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot. Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate. Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Over-speed protection The speed of the robot is monitored by two independent computers. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. Safeguarded space stop The controller has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors shuts off. Collision detection In case an unexpected mechanical disturbance like a collision, electrode stik etc appears, the robot will stop and slightly back off from its stop position. Restricting the working space The movement of each axis can be restricted using software limits. There are safeguarded space stops for connection of limit switches to restrict the working space. For some robots the axes 1-3 can also be restricted by means of mechanical stops. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety. Safety lamp As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the controller is in the MOTORS ON state.

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Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.3 Operation All operations and programming can be carried out using the portable teach pendant (see Figure 3) and operator’s panel (see Figure 5). .

Hold-to-run Menu keys

Motion keys

Display

P5 P4 7 4 1

Window keys 1 2

P1

8 5 2 0

9 6 3

Joystick

Enabling device

P2 P3

Function keys

Emergency stop button Navigation keys

Cable 10 m Figure 3 The teach pendant is equipped with a large display, which displays prompts, information, error messages and other information in plain English.

Information is presented on a display using windows, pull-down menus, dialogs and function keys. No previous programming or computer experience is required to learn how to operate the robot. All operations can be carried out from the teach pendant, which means that an additional keyboard is not required. All information, including the complete programming language, is in English or, if preferred, some other major language. (Available languages, see options on page 32). Display Displays all information during programming, to change programs, etc. 16 text lines with 40 characters per line. Motion keys Select the type of movement when jogging. Navigation keys Used to move the cursor within a window on the display and enter data. Menu keys Display pull-down menus, see Figure 4. Function keys Select the commands used most often. Window keys Display one of the robot’s various windows. These windows control a number of different functions: - Jog (manual operation) - Program, edit and test a program - Manual input/output management Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description - File management - System configuration - Service and troubleshooting - Automatic operation User-defined keys (P1-P5) Five user-defined keys that can be configured to set or reset an output (e.g. open/close gripper) or to activate a system input. Hold-to-run A push button which must be pressed when running the program in manual mode with full speed. Enabling device A push button which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. Joystick The joystick is used to jog (move) the robot manually; e.g. when programming the robot. Emergency stop button The robot stops immediately when the button is pressed in.

Menu keys File

Edit View 1 Goto ... Inputs/Outputs 2 Goto Top 3 Goto Bottom Name Value

I/O list

di1 di2 grip1 grip2 clamp3B feeder progno 1

1 0 1 0 1 1 13

Menu 4(6)

Line indicator

Cursor

0

Function keys

Figure 4 Window for manual operation of input and output signals.

Using the joystick, the robot can be manually jogged (moved). The user determines the speed of this movement; large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly. The robot supports different user tasks, with dedicated windows for: - Production 8

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description - Programming - System setup - Service and installation Operator’s panel

MOTORS ON button and indicating lamp

Operating mode selector

Emergency stop If pressed in, pull to release

Duty time counter Indicates the operating time for the manipulator (released brakes)

MOTORS ON Continuous light Fast flashing light (4Hz)

= Ready for program execution = The robot is not calibrated or the revolution counters are not updated Note: The motors have been switched on

Slow flashing light (1 Hz) = One of the safeguarded space stops is active Note: The motors have been switched off

Operating mode selector Using a key switch, the robot can be locked in two (or three) different operating modes depending on chosen mode selector:

100%

Automatic mode

= Running production

Manual mode at reduced speed

= Programming and setup Max. speed 250 mm/s (600 inches/min.)

As optional: Manual mode = Testing at full program speed at full speed Equipped with this mode, the robot is not approved according to ANSI/UL

Figure 5 The operating mode is selected using the operator’s panel on the controller.

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Description Both the operator’s panel and the teach pendant can be mounted externally, i.e. outside the cabinet. The robot can then be controlled from there. The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals. For more information on how to operate the robot, see the User’s Guide.

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Product Specification S4Cplus M2000/BaseWare OS 4.0

Description 1.4 Memory Available memory The controller has two different memories: - a fixed RAM memory of size 32 MB, used as working memory - a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB. The RAM memory is used for running the system software and the user programs, and it is thus divided into three areas: - system software - system software execution data - user RAPID programs, about 5.5 MB, see Figure 6 (when installing different options, the user program memory will decrease, at most with about 0.7 MB). The flash disk is divided into four main areas: - a base area of 5 MB, with permanent code for booting - a release area of 20 MB, where all the code for a specific release is stored - a system specific data area of 10 MB, where all the run time specific data including the user program for a system is stored at backup - a user mass memory area which can be used for storing RAPID programs, data, logs etc. The flash disk is used for backup, i.e. when power failure occurs or at power off, all the system specific data including the user program, see Figure 6, will be stored on the flash disk and restored at power on. A backup power system ensure the automatic store function. RAM memory 32 MB

Flash disk memory 64/128 MB Boot 5 MB

System soft ware

Release storage 20 MB

Data

User RAPID program 5.5 MB

System data and user program 10 MB Power on restore

Power off store

Mass memory area available for the user

Figure 6 Available memory.

Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description Several different systems, i.e. process applications, may be installed at the same time in the controller, of which one can be active. Each such application will occupy another 10 MB of the flash memory for system data. The release storage area will be in common as long as the process applications are based on the same release. If two different releases should be loaded, the release storage area must also be doubled. For RAPID memory consumption, see RAPID Developer’s Manual. As an example, a MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the instruction (marked with ‘*’) and 168 bytes if a named robtarget is used. In the latter case, the CONST declaration of the named robtarget consumes an additional 280 bytes. Additional software options will reduce the available user program memory, most of them however only marginally, i.e. the user program area will still be about 5.5 MB. Only the SpotWare option will reduce memory significantly, i.e. down to about 4.8 MB depending on the number of simultaneous welding guns.

1.5 Installation The controller is delivered with a standard configuration for the corresponding manipulator, and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the teach pendant. Operating requirements Protection standards Controller electronic Controller air ducts

IEC529 IP54 IP 30

Explosive environments The controller must not be located or operated in an explosive environment. Ambient temperature Controller during operation

+5oC (41oF) to +45oC (113oF) with option 473 +52oC (125oF) Complete robot during transportation and storage, -25oC (13oF) to +42oC (107oF) for short periods (not exceeding 24 hours) up to +70oC (158oF) Relative humidity Transportation, storage and operation

Max. 95% at constant temperature

Power supply Mains voltage Mains voltage tolerance

200-600 V, 3p (3p + N for certain options +10%,-15%

Mains frequency

48.5 to 61.8 Hz

Rated power (transformer size): IRB 140, 1400, 2400 IRB 340, 14001, 24001,4400, 6400 External axes drives in separate cabinet

4.5 kVA 7.8 kVA 7.2 kVA

Computer system backup capacity at power interrupt

20 sec (rechargeable battery)

1. Enlarged transformer for external axes 12 Product Specification S4Cplus M2000/BaseWare OS 4.0

Description Configuration The robot is very flexible and can, by using the teach pendant, easily be configured to suit the needs of each user: Authorisation Most common I/O Instruction pick list Instruction builder Operator dialogs Language Date and time Power on sequence EM stop sequence Main start sequence Program start sequence Program stop sequence Change program sequence Working space External axes Brake delay time I/O signal Serial communication

Password protection for configuration and program window User-defined lists of I/O signals User-defined set of instructions User-defined instructions Customised operator dialogs All text on the teach pendant can be displayed in several languages Calendar support Action taken when the power is switched on Action taken at an emergency stop Action taken when the program is starting from the beginning Action taken at program start Action taken at program stop Action taken when a new program is loaded Working space limitations Number, type, common drive unit, mechanical units Time before brakes are engaged Logical names of boards and signals, I/O mapping, cross connections, polarity, scaling, default value at start up, interrupts, group I/O Configuration

For a detailed description of the installation procedure, see the Product Manual Installation and Commissioning.

1.6 Programming Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”. The programming environment can be easily customized using the teach pendant. - Shop floor language can be used to name programs, signals, counters, etc. - New instructions can be easily written. - The most common instructions can be collected in easy-to-use pick lists. - Positions, registers, tool data, or other data, can be created. Programs, parts of programs and any modifications can be tested immediately without having to translate (compile) the program.

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Description Movements A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move. The end position of a movement is selected either by manually jogging the robot to the desired position with the joystick, or by referring to a previously defined position. The exact position can be defined (see Figure 7) as: - a stop point, i.e. the robot reaches the programmed position or - a fly-by point, i.e. the robot passes close to the programmed position. The size of the deviation is defined independently for the TCP, the tool orientation and the external axes. Stop point

Fly-by point User-definable distance (in mm)

Figure 7 The fly-by point reduces the cycle time since the robot does not have to stop at the programmed point. The path is speed independent.

The velocity may be specified in the following units: - mm/s - seconds (time it takes to reach the next programmed position) - degrees/s (for reorientation of the tool or for rotation of an external axis) Program management For convenience, the programs can be named and stored in different directories. The mass memory can also be used for program storage. These can then be automatically downloaded using a program instruction. The complete program or parts of programs can be transferred to/from the network or a diskette. The program is stored as a normal PC text file, which means that it can be edited using a standard PC. Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, undo etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane. A robot position can easily be changed either by 14

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description - jogging the robot with the joystick to a new position and then pressing the “ModPos” key (this registers the new position) or by - entering or modifying numeric values. To prevent unauthorised personnel from making program changes, passwords can be used. Testing programs Several helpful functions can be used when testing programs. For example, it is possible to - start from any instruction - execute an incomplete program - run a single cycle - execute forward/backward step-by-step - simulate wait conditions - temporarily reduce the speed - change a position - tune (displace) a position during program execution. For more information, see the User’s Guide and RAPID Reference Manual.

1.7 Automatic Operation A dedicated production window with commands and information required by the operator is automatically displayed during automatic operation. The operation procedure can be customised to suit the robot installation by means of user-defined operating dialogs.

Select program to run:

Front A Front B Front C

Other

SERVICE

Figure 8 The operator dialogs can be easily customised.

A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution. You can also create special routines that will be automatically executed when the power Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description is switched on, at program start and on other occasions. This allows you to customise each installation and to make sure that the robot is started up in a controlled way. The robot is equipped with absolute measurement, making it possible to operate the robot directly when the power is switched on. For your convenience, the robot saves the used path, program data and configuration parameters so that the program can be easily restarted from where you left off. Digital outputs are also set automatically to the value prior to the power failure.

1.8 The Rapid Language and Environment The Rapid language is a well balanced combination of simplicity, flexibility and powerfulness. It contains the following concepts: - Hierarchical and modular program structure to support structured programming and reuse. - Routines can be Functions or Procedures. - Local or global data and routines. - Data typing, including structured and array data types. - User defined names (shop floor language) on variables, routines and I/O. - Extensive program flow control. - Arithmetic and logical expressions. - Interrupt handling. - Error handling (for exception handling in general, see Exception handling). - User defined instructions (appear as an inherent part of the system). - Backward handler (user definition of how a procedure should behave when stepping backwards). - Many powerful built-in functions, e.g mathematics and robot specific. - Unlimited language (no max. number of variables etc., only memory limited). Windows based man machine interface with built-in Rapid support (e.g. user defined pick lists).

1.9 Exception handling Many advanced features are available to make fast error recovery possible. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time. Examples: - Error Handlers (automatic recovery often possible without stopping production). - Restart on Path. - Power failure restart. - Service routines. 16

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description - Error messages: plain text with remedy suggestions, user defined messages. - Diagnostic tests. - Event logging.

1.10 Maintenance and Troubleshooting The controller requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - The controller is enclosed, which means that the electronic circuitry is protected when operating in a normal workshop environment. - There is a supervision of temperature, fans and battery health. The robot has several functions to provide efficient diagnostics and error reports: - It performs a self-test when power on is set. - Computer status LEDs and console (serial channel) for fault tracing support. - Errors are indicated by a message displayed in plain language. The message includes the reason for the fault and suggests recovery action. - Faults and major events are logged and time-stamped. This makes it possible to detect error chains and provides the background for any downtime. The log can be read on the teach pendant display, stored in a file or printed on a printer. - There are commands and service programs in RAPID to test units and functions. - LEDs on the panel unit indicate status of the safeguarded switches. Most errors detected by the user program can also be reported to and handled by the standard error system. Error messages and recovery procedures are displayed in plain language. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.

1.11 Robot Motion Motion concepts QuickMoveTM The QuickMoveTM concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement. - No parameters have to be adjusted to achieve correct path, orientation and velocity. - Maximum acceleration is always obtained (acceleration can be reduced, e.g. Product Specification S4Cplus M2000/BaseWare OS 4.0

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Description when handling fragile parts). - The number of adjustments that have to be made to achieve the shortest possible cycle time is minimized. TrueMoveTM The TrueMoveTM concept means that the programmed path is followed – regardless of the speed or operating mode – even after an emergency stop, a safeguarded stop, a process stop, a program stop or a power failure. This very accurate path and speed is based on advanced dynamic modelling. Coordinate systems BaseWare includes a very powerful concept of multiple coordinate systems that facilitates jogging, program adjustment, copying between robots, off-line programming, sensor based applications, external axes co-ordination etc. Full support for TCP (Tool Centre Point) attached to the robot or fixed in the cell (“Stationary TCP”). Tool Centre Point (TCP) Y

Tool coordinates Z

Base coordinates

X Y

Z

Axis 3

Axis 2

Y

Axis 3

Y

X Base coordinates

X

Axis 1

Z

X

Axis 1

Y Tool coordinates

Z Tool Centre Point (TCP)

Z

X

Z

Z User coordinates Y

Y

Object coordinates Y X

World coordinates X X Figure 9 The coordinate systems, used to make jogging and off-line programming easier.

18

The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop. The world coordinate system is also very useful when two robots work together or when using a robot carrier. Product Specification S4Cplus M2000/BaseWare OS 4.0

Description The base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tool’s centre point and orientation. The user coordinate system specifies the position of a fixture or workpiece manipulator. The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator. The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed). Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool. If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined. Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object. Program execution The robot can move in any of the following ways: - Joint motion (all axes move individually and reach the programmed position at the same time). - Linear motion (the TCP moves in a linear path). - Circle motion (the TCP moves in a circular path). Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur. If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part. Jogging The robot can be manually operated in any one of the following ways: - Axis-by-axis, i.e. one axis at a time. - Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate systems mentioned above). - Reoriented around the TCP. It is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved. Product Specification S4Cplus M2000/BaseWare OS 4.0

19

Description During manual operation, the current position of the robot and the external axes can be displayed on the teach pendant. Singularity handling The robot can pass through singular points in a controlled way, i.e. points where two axes coincide. Motion Supervision The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not OK. A further monitoring function, Collision Detection, is optional (see option “Load Identification and Collision Detection”). External axes Very flexible possibilities to configure external axes. Includes for instance high performance coordination with robot movement and shared drive unit for several axes. Big Inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. For big, flexible objects it is possible to optimise the servo tuning to minimise load oscillation. Soft Servo Any axis (also external) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour.

1.12 External Axes The robot can control up to six external axes. These axes are programmed and moved using the teach pendant in the same way as the robot’s axes. The external axes can be grouped into mechanical units to facilitate, for example, the handling of robot carriers, workpiece manipulators, etc. The robot motion can be simultaneously coordinated with for example, a one-axis linear robot carrier and a rotational external axis. A mechanical unit can be activated or deactivated to make it safe when, for example, manually changing a workpiece located on the unit. In order to reduce investment costs, any axes that do not have to be active at the same time, can share the same drive unit. An external axis is an AC motor (IRB motor type or similar) controlled via a drive unit mounted in the robot cabinet or in a separate enclosure. See Specification of Variants and Options. 20

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description Resolver

Connected directly to motor shaft Transmitter type resolver Voltage ratio 2:1 (rotor: stator) 5.0 V/4 kHz

Resolver supply

Absolute position is accomplished by battery-backed resolver revolution counters in the serial measurement board (SMB). The SMB is located close to the motor(s) according to Figure 10. For more information on how to install an external axis, see the Product Manual Installation and Commissioning. When more than one external axis is used, the drive units for external axis 2 and upwards must be placed in a separate cabinet according to Figure 10. Not supplied on delivery Multiple external axis

Measurement System 2

SMB

alt. Drive system 2

ABB drives

Single external axis

Not supplied on delivery User designed cabinet (non-ABB drives)

Measurement System 1

SMB

Motor channel Serial signals for measurement and drive system

Not supplied on delivery

Figure 10 Outline diagram, external axes.

Product Specification S4Cplus M2000/BaseWare OS 4.0

21

Description

1.13 Inputs and Outputs A distributed I/O system, built on CAN/DeviceNet, is used, which makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. Two independant DeviceNet buses allow various conditions of I/O handling. One bus, CAN1, is always operating as master from S4Cplus with a fixed data rate. The other (accessible by the software option I/O Plus), CAN2, is configurable for both master or slave operation and with different data rates. tap

thick/thin cable

S4Cplus

multiport-tap

R

trunk line

R node

thick/thin cable

node node

I/O CPU node

Daisy chain

node node

node

node R = terminating resistor short drop max. 6m each Figure 11 Example of a general DeviceNet bus.

A number of different input and output units can be installed: - Digital inputs and outputs. - Analog inputs and outputs. - Gateway (slave) for Allen-Bradley PLC. - Gateway (slave) for Interbus-S Slave. - Gateway (slave) for Profibus DP Slave. S4Cplus with the option I/O Plus can be configured for DeviceNet units from other suppliers. For more details see the Product Specification RobotWare Options. The inputs and outputs can be configured to suit your installation: - Each signal and unit can be given a name, e.g. gripper, feeder. - I/O mapping (i.e. a physical connection for each signal). - Polarity (active high or low). - Cross connections. - Up to 16 digital signals can be grouped together and used as if they were a single signal when, for example, entering a bar code. - Sophisticated error handling. - Selectable “trust level” (i.e. what action to take when a unit is “lost”). 22

- Program controlled enabling/disabling of I/O units. Product Specification S4Cplus M2000/BaseWare OS 4.0

Description - Scaling of analog signals. - Filtering. - Polarity definition. - Pulsing. - TCP-proportional analog signal. - Programmable delays. - Simulated I/O (for forming cross connections or logical conditions without need the for physical hardware). - Accurate coordination with motion. Signals can be assigned to special system functions, such as program start, so as to be able to control the robot from an external panel or PLC. The robot can work as a PLC by monitoring and controlling I/O signals: - I/O instructions can be executed concurrent to the robot motion. - Inputs can be connected to trap routines. (When such an input is set, the trap routine starts executing. Following this, normal program execution resumes. In most cases, this will not have any visible effect on the robot motion, i.e. if a limited number of instructions are executed in the trap routine.) - Background programs (for monitoring signals, for example) can be run in parallel with the actual robot program. Requires Multitasking option, see Product Specification RobotWare. Manual functions are available to: - List all the signal values. - Create your own list of your most important signals. - Manually change the status of an output signal. - Print signal information on a printer. I/O signals can for some robots also be routed parallel or serial to connectors on the upper arm of the robot. Types of connection The following types of connection are available: - “Screw terminals” on the I/O units - Industrial connectors on cabinet wall - Distributed I/O-connections inside or on cabinet wall For more detailed information, see Chapter 2, Specification of Variants and Options. I/O units (node types) Several I/O units can be used. The following table shows the maximum number of physical signals that can be used on each unit. Data rate is fixed at 500 Kbit/s.

Product Specification S4Cplus M2000/BaseWare OS 4.0

23

Description

Digital Type of unit

Analog

Option no.

In

Out

Digital I/O 24 VDC

20x

16

16

Internal/External1

Digital I/O 120 VAC

25x

16

16

Internal/External

Analog I/O

22x

AD Combi I/O

23x

16

16

Relay I/O

26x

16

16

Allen-Bradley Remote I/O Slave

281

1282

128

Interbus-S Slave

284-285

642

64

Profibus DP Slave

286-287

1282

128

100

100

4

Simulated I/O3 Encoder interface unit4

Voltage inputs

288-289

Voltage output

3

Current output

1

Power supply

Internal Internal/External1

2

Internal/External1

30

30

1

1. The digital signals are supplied in groups, each group having 8 inputs or outputs. 2. To calculate the number of logical signals, add 2 status signals for RIO unit and 1 for Interbus-S and Profibus DP. 3. A non physical I/O unit can be used to form cross connections and logical conditions without physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit. 4. Dedicated for conveyor tracking only.

Distributed I/O The total number of logical signals is 1024 per DeviceNet bus (inputs or outputs, group I/O, analog and digital including field buses) CAN1 Max. total no of units* Data rate (fixed) Max. total cable length Cable type (not included)

CAN2 (option)

20 (including SIM units) 20 500 Kbit/s 125/250/500 Kbit/s. 100 m trunk + 39m drop up to 1000m According to DeviceNet specification release 1.2

* Max. four units can be mounted inside the cabinet. Signal data Permitted customer 24 V DC load Digital inputs 24 V DC

24

(option 201/203) Optically-isolated Rated voltage: Logical voltage levels: “1” “0” Input current at rated input voltage: Potential difference: max.

max. 7,5 A

24 V DC 15 to 35 V -35 to 5 V 6 mA 500 V

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description Time delays:

hardware software

Time variations:

5−15 ms ≤ 3 ms ± 2 ms

Digital outputs (option 201/203) 24 V DC Optically-isolated, short-circuit protected, supply polarity protection Voltage supply 19 to 35 V Rated voltage 24 V DC Logical voltage levels: “1” 18 to 34 V “0” <7V Output current: max. 0.5 A Potential difference: max. 500 V Time delays: hardware ≤ 1 ms software ≤ 2 ms Time variations: ± 2 ms Relay outputs

Digital inputs 120 V AC

(option 205) Single pole relays with one make contact (normally open) Rated voltage: 24 V DC, 120 VAC Voltage range: 19 to 35 V DC 24 to 140 V AC Output current: max. 2 A Potential difference: max. 500V Time intervals: hardware (set signal) typical 13 ms hardware (reset signal) typical 8 ms software ≤ 4 ms (option 204) Optically isolated Rated voltage Input voltage range: “1” Input voltage range: “0” Input current (typical): Time intervals: hardware software

120 V AC 90 to 140 V AC 0 to 45 V AC 7.5 mA ≤ 20 ms ≤ 4 ms

Digital outputs 120 V AC (option 204) Optically isolated, voltage spike protection Rated voltage 120 V AC Output current: max. 1A/channel, 12 A 16 channels or max. 2A/channel, 10 A 16 channels (56 A in 20 ms) min. 30mA Voltage range: 24 to 140 V AC Potential difference: max. 500 V Off state leakage current: max. 2mA rms On state voltage drop: max. 1.5 V Time intervals: hardware ≤ 12 ms software ≤ 4 ms

Product Specification S4Cplus M2000/BaseWare OS 4.0

25

Description Analog inputs (option 202) Voltage Input voltage: Input impedance: Resolution: Accuracy: Analog outputs

Analog outputs

(option 202) VoltageOutput voltage: Load impedance: Resolution: CurrentOutput current: Load impedance: Resolution: Accuracy:

+10 V >1 Mohm 0.61 mV (14 bits) +0.2% of input signal

min. min.

+10 V 2 kohm 2.44 mV (12 bits) 4-20 mA 800 ohm 4.88 µA (12 bits) +0.2% of output signal

(option 203) Output voltage (galvanically isolated): Load impedance: min. Resolution: Accuracy: Potential difference: Time intervals: hardware software

0 to +10 V 2 kohm 2.44 mV (12 bits) ±25 mV ±0.5% of output voltage max. 500 V ≤ 2.0 ms ≤ 4 ms

System signals Signals can be assigned to special system functions. Several signals can be given the same functionality. Digital outputs

Motors on/off Executes program Error Automatic mode Emergency stop Restart not possible Run chain closed

Digital inputs

Motors on/off Starts program from where it is Motors on and program start Starts program from the beginning Stops program Stops program when the program cycle is ready Stops program after current instruction Executes “trap routine” without affecting status of stopped regular program1 Loads and starts program from the beginning1 Resets error Resets emergency stop System reset

Analog output

TCP speed signal

1. Program can be decided when configuring the robot.

For more information on system signals, see User’s Guide - System Parameters. 26

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.14 Communication The controller has three serial channels for permanent use - two RS232 and one RS422 Full duplex - which can be used for communication point to point with printers, terminals, computers and other equipment. For temporary use, like service, there are two more RS 232 channels. The serial channels can be used at speeds of 300 to 19200 bit/s (max. 1 channel with speed 19200 bit/s).

Temporary RS 232 or Ethernet 10 MB/s

Permanent Figure 12 Point-to-point communication.

The controller has two Ethernet channels, one can be used at 10 MB/s, the other at up to 100 MB/s. The communication includes TCP/IP with intensive network configuration possibilities like: - DNS, DHCP etc. (including multiple gateway) - Network file system accesses using FTP client and server - Control and/or monitoring of controllers with RAP protocol makes it possible to use OPC, ActiveX, and other APIs for integration with Window applications - Boot/upgrading of controller software via the network or a portable PC.

10 MB

10 MB

10 MB

Ethernet up to 100 MB/s Figure 13 Network communication.

Product Specification S4Cplus M2000/BaseWare OS 4.0

27

Description

28

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

2 Specification of Variants and Options The different variants and options for the controller are described below. The same numbers are used here as in the Specification form. For manipulator options, see Product Specification respectively, and for software options, see Product Specification RobotWare Options. Note Options marked with * are inconsistent with UL/UR approval.

1 SAFETY STANDARDS EU - Electromagnetic Compatibility 693 The controller complies with the European Union Directive “Electromagnetic Compatibility” 89/336/EEC. This option is required by law for end users in the European Union.

UNDERWRITERS LABORATORY 695 UL Listed, certificate on product level. Underwriters Laboratories Inc. has tested and examined the finished complete product, i.e. manipulator and controller, and determined that the product fulfils the stipulated safety standards. Some options marked with * are inconstistent with UL Listed. Option 112 Standard cabinet without upper cover can not be UL Listed at delivery, it may be ordered as UL Recognized. Not available for IRB 340, 6400PE. 696 UR Recognized, certificate on component level. Underwriters Laboratories Inc. has tested and examined the components in the product, manipulator and controller, and determined that they fulfil the stipulated safety standards. Not available for IRB 340.

2 CONTROL SYSTEM CABINET Variant 111 Standard cabinet with upper cover. 112* Prepared for Arcitec Not available for IRB 340, 4400, 640, 6400R, 6400PE, 6400S, 840 Cabinet Height 121 Standard cabinet with upper cover. 122* Standard cabinet without upper cover. To be used when cabinet extension is mounted on top of the cabinet after delivery. Product Specification S4Cplus M2000/BaseWare OS 4.0

29

Specification of Variants and Options 123* Standard cabinet with 250 mm extension. The height of the cover increases the available space for external equipment that can be mounted inside the cabinet. 124* The extension is mounted on top of the standard cabinet. There is a mounting plate inside. (See Figure 14). The cabinet extension is opened via a front door and it has no floor. The upper part of the standard cabinet is therefore accessible. This option cannot be combined with options 141 together with 145.

Shaded area 40x40 (four corners) not available for mounting

705

730 Figure 14 Mounting plate for mounting of equipment (dimensions in mm)

126 Cabinet on wheels. Increase the height by 30 mm.

OPERATOR’S PANEL The operator’s panel and teach pendant holder can be installed in different ways. 181 Standard, i.e. on the front of the cabinet. 182 External, i.e. in a separate operator’s unit. (See Figure 15 for required preparation) All necessary cabling, including flange, connectors, sealing strips, screws, etc., is supplied. External enclosure is not supplied. 183 External, mounted in a box. (See Figure 16)

30

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

M4 (x4) M8 (x4) 45o

Required depth 200 mm

196

193

180 224 240

223

70

62 140

96 Holes for flange

184 200 Holes for operator’s panel

External panel enclosure (not supplied)

Holes for teach pendant holder

Teach pendant connection

90

155

5 (x2)

Connection to the controller

Figure 15 Required preparation of external panel enclosure (all dimensions in mm).

M5 (x4) for fastening of box

337

Connection flange 370 Figure 16 Operator’s panel mounted in a box (all dimensions in mm).

Product Specification S4Cplus M2000/BaseWare OS 4.0

31

Specification of Variants and Options OPERATOR’S PANEL CABLE 185 15 m 186 22 m 187 30 m

DOOR KEYS 461 462 463 464 466

Standard Doppelbart Square outside 7 mm EMKA DB Locking cylinder 3524

OPERATING MODE SELECTOR 193 Standard, 2 modes: manual and automatic. 191* Standard, 3 modes: manual, manual full speed and automatic.

CONTROLLER COOLING 472 Environment temperature up to 45oC (113oF) 473 Harsh environment and temperature up to 52oC (125oF)

TEACH PENDANT 601 Teach pendant with back lighting Teach pendant language: 611 612 613 614 615 617 618 619 620 621

English Swedish German French Spanish Danish Italian Dutch Japanese Czech Extension cable for the teach pendant:

606 10 m This can be connected between the controller and the connector on the teach pendant’s cable. A maximum of two extension cables may be used; i.e. the total length of cable between the controller and the teach pendant should not exceed 30 m. 607 20 m

32

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options MAINS VOLTAGE The robot can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible in each connection. 151- Voltage 163 200 V 220 V 400 V 440 V

Voltage

400 V 440 V 475 V 500 V

Voltage

475 V 500 V 525 V 600 V

MAINS CONNECTION TYPE The power is connected either inside the cabinet or to a connector on the cabinet’s lefthand side. The cable is not supplied. If option 133-136 is chosen, the female connector (cable part) is included. 131 Cable gland for inside connection. Diameter of cable: 11-12 mm. 132* 32 A, 380-415 V, 3p + PE (see Figure 17). 133* 32 A, 380-415 V, 3p + N + PE (see Figure 17). Figure 17 CEE male connector.

134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640. 35 A, 600 V, 6p + PE (see Figure 18).

Figure 18 DIN male connector.

MAINS SWITCH 141* Rotary switch in accordance with the standard in section 3.2 and IEC 337-1, VDE 0113. Customer fuses for cable protection required. 142 Flange disconnect (20 A) in accordance with the standard in section 3.2. Includes door interlock. Interrupt capacity 14 kA. 144 Servo disconnector. This option adds a mechanical switch to the two series connected motors on contactors. The switch is operated by the same type of handle as the rotary mains switch. The handle can be locked by a padlock, e.g. in an off position. 145* Door interlock. Includes rotary switch. 147 Circuit breaker for rotary switch. A 16 A (transformer 2 and 3) or 25 A (transformer 1) circuit breaker for short circuit protection of mains cables in the cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660. Interrupt capacity 3 kA. 148 Fuses (3x15 A) for the rotary switch for short circuit protection of mains cables in the cabinet. Interrupt capacity 50 kA. Product Specification S4Cplus M2000/BaseWare OS 4.0 33

Specification of Variants and Options I/O INTERFACES The standard cabinet can be equipped with up to four I/O units. For more details, see page 22. X6 (CAN 1.2) X7 (CAN 1.3)

X8 (CAN 2)

Base Connector Unit

X10 (SIO1) X9 (SIO2) X15 (CAN1.1)

Cabinet view from above I/O Units (X4)

Computersystem (COM2) XT 31 (24V I/O)

Panel Unit

Manipulator connections

X1-X4 Safety Signals

115/230 VAC

XT21

Connection to Position switches

XP6

XP5

XP58

XP8

Connection to Customer power Customer signals Figure 19 I/O unit and screw terminal locations.

34

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options 201 Digital 24 VDC I/O: 16 inputs/16 outputs. 202 Analog I/O: 4 inputs/4 outputs. 203 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 204 Digital 120 VAC I/O 16 inputs/16 outputs. 205 Digital I/O with relay outputs: 16 inputs/16 outputs. Relay outputs to be used when more current or voltage is required from the digital outputs. The inputs are not separated by relays. Connection of I/O 251 Internal connection (options 201-204, 221-224, 231-234, 251-254, 261-264) The signals are connected directly to screw terminals on the I/O units in the upper part of the cabinet (see Figure 19). 252 External connection The signals are connected via 64-pole standard industrial connector in accordance with DIN 43652. The connector is located on the left-hand side of the controller. Corresponding customer part is included.

SAFETY SIGNALS 206 Internal connection The signals are connected directly to screw terminals in the upper part of the cabinet (see Figure 19). 207 External connection The signals are connected via 64-pole standard industrial connector in accordance with DIN 43652. The connector is located on the left-hand side of the controller. Corresponding customer part is included.

DEVICENET ON LEFT WALL 245 DeviceNet Connection on the left side to two 5-pole male connectors in accordance with ANSI. (Female connectors are supplied).

GATEWAY UNITS For more details, see Inputs and Outputs on page 22. 241 Allen-Bradley Remote I/O Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the number of I/O units that can be mounted in cabinet by one. The field bus cables are connected directly to the A-B RIO unit in the upper part of the cabinet (see Figure 19). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included. 242 Interbus-S Slave Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC equipped with an InterBus-S interface. The unit reduces the number of I/O units that

Product Specification S4Cplus M2000/BaseWare OS 4.0

35

Specification of Variants and Options can be mounted in the cabinet by one. The signals are connected directly to the InterBus-S slave unit (two 9-pole D-sub) in the upper part of the cabinet. 243 Profibus DP Slave Up to 128 digital inputs and 128 digital outputs can be transferred serially to a PLC equipped with a Profibus DP interface. The unit reduces the number of I/O units that can be mounted in the cabinet by one. The signals are connected directly to the Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet. 244 Encoder interface unit for conveyor tracking Conveyor Tracking, or Line Tracking, is the function whereby the robot follows a work object which is mounted on a moving conveyor. The encoder and synchronization switch cables are connected directly to the encoder unit in the upper part of the cabinet (see Figure 19). Screw connector is included. For more information see Product Specification RobotWare.

EXTERNAL I/O UNITS I/O units can be delivered separately. The units can then be mounted outside the cabinet or in the cabinet extension. These are connected in a chain to a connector (CAN 3 or CAN 2, see Figure 19) in the upper part of the cabinet. Connectors to the I/O units and a connector to the cabinet (Phoenix MSTB 2.5/xx-ST-5.08), but no cabling, is included. Dimensions according to Figure 20 and Figure 21. For more details, see Inputs and Outputs on page 22. 221 Digital I/O 24 V DC: 16 inputs/16 outputs. 222 Analog I/O. 223 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 224 Digital I/O 120 V AC: 16 inputs/16 outputs. 225 Digital I/O with relay outputs: 16 inputs/16 outputs.

EXTERNAL GATEWAY UNITS 231 Allen Bradley Remote I/O 232 Interbus-S Slave 233 Profibus DP Slave 234 Encoder interface unit for conveyor tracking

36

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

EN 50022 mounting rail

195

203

49

Figure 20 Dimensions for units 221-225.

EN 50022 mounting rail

170

115

49

Figure 21 Dimension for units 231-234.

EXTERNAL AXES IN ROBOT CABINET (not available for IRB 340, IRB 6400PE) It is possible to equip the controller with drives for external axes. The motors are connected to a standard industrial 64-pin female connector, in accordance with DIN 43652, on the left-hand side of the cabinet. (Male connector is also supplied.) 391 Drive unit C The drive unit is part of the DC-link. Recommended motor type see Figure 22. Not available for IRB 640, 6400R, 6400S. 392 Drive unit T The drive unit is part of the DC-link. Recommended motor type see Figure 22. Not available for IRB 640 6400R, 6400S. 393 Drive unit GT A separate drive unit including two drives. Recommended motor type see Figure 22. Not available for IRB 4400, 6400R, 6400S

Product Specification S4Cplus M2000/BaseWare OS 4.0

37

Specification of Variants and Options 394 Drive unit T+GT A combination of 392 and 393. Not available for IRB 4400, 640, 6400R, 6400S 395 Drive unit C+GT A combination of 391 and 393 Not available for IRB 4400, 640, 6400R, 6400S 396 Prepared for drives No drive units or cables are included, only transformer 7.2 kVA and DC link DC2. Not available for IRB 4400, 640, 6400R, 6400S 397 Drive unit U The drive unit is part of the DC-link. Recommended motor types see Figure 22. Not available for IRB 140, 1400, 2400, 4400, 640 365 Trackmotion Only with 394 or 395.

EXTERNAL AXES MEASUREMENT BOARD (not available for IRB 340, IRB 6400PE) The resolvers can be connected to a serial measurement board outside the controller. 387 Serial measurement board as separate unit

EXTERNAL AXES - SEPARATE CABINET (not available for IRB 340, IRB 6400PE) An external cabinet can be supplied when there is not space enough in the standard cabinet. The external cabinet is connected to one Harting connector (cable length 7 m) on the left-hand side of the robot controller. Door interlock, mains connection, mains voltage and mains filter according to the robot controller. One transformer and one mains switch are included. 371/372 Drive unit GT, for 4 or 6 motors. Recommended motor types see Figure 22.

38

373

Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 22.

374

Drive unit GT + ECB

375

Drive unit GT + GT + ECB

376

External drive system Industrial connector and 7 m cable for DMC/FBU drive unit supplied by Atlas Copco Controls. The option Advanced Motion is required.

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

Drive unit data

Max current

Rated current

Motor type1

U

11 - 55A rms

24A rms

M, L

G

6 - 30A rms

16A rms

S, M, L

T

7,5 - 37A rms

20A rms

S, M, L

E

4 - 19A rms

8,4A rms

C

2,5 - 11A rms

5A rms

B

1,5 - 7A rms

4A rms

1. Motors from ABB Flexible Automation/System Products. Types: S=small (TN=1,7 Nm), M=medium (TN=5 Nm), L=large (TN=12 Nm) Figure 22 Motor selecting table.

EQUIPMENT Manipulator cable, external connectors 653 Standard 654 Metal braided Only together with 641 or 642. Not available for IRB 340 and protection foundry. 655 Foundry (only for IRB 4400) Cable length 641 642 643 644 649

7m 15 m, not available for IRB 140 22 m, not available for IRB 140 30 m, not available for IRB 140 3 m, only available for IRB 140 Manipulator connection (only available for IRB 340)

657 External (not for the SA-version i.e. WashDown) 658 Internal

SERVICE OUTLET Any of the following standard outlets with protective earthing can be chosen for maintenance purposes. The maximum load permitted is 500 VA (max. 100 W can be installed inside the cabinet). 411 120 V in accordance with American standard; single socket, Harvey Hubble. 412* 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for Sweden, Germany and other countries. Product Specification S4Cplus M2000/BaseWare OS 4.0

39

Specification of Variants and Options POWER SUPPLY 431 Connection from the main transformer. The voltage is switched on/off by the mains switch on the front of the cabinet. 432 Connection before mains switch without transformer. Note this only applies when the mains voltage is 400 V, three-phase with neutral connection and a 230 V service socket. Note! Connection before mains switch is not in compliance with some national standards, NFPL 79 for example.

MEMORY Removable mass memory 320 Floppy drive Extended mass memory 310 Flash disc 128 Mb. Standard is 64 Mb

40

Product Specification S4Cplus M2000/BaseWare OS 4.0

Index

3 Index

F

A

fire safety 6 flash disk memory 11 fly-by point 14 function keys 7

absolute measurement 16 Allen-Bradley Remote I/O 22, 24, 35 analog signals 22, 26 automatic operation 15 B backup computer system backup 12 memory 11 Big Inertia 20 C cabinet wheels 30 communication 27 concurrent I/O 23 configuration 12, 13, 22 connection 40 mains supply 33 cooling device 3 coordinate systems 18 cross connections 22 cursor 7 D DeviceNet 35 diagnostics 17 digital signals 22, 24 display 7 distributed I/O 24 E editing position 14 programs 14 emergency stop 6, 7 enabling device 5 display 7 Encoder interface unit 24, 36 event routine 15 extended memory 11 external axes 20 external panel 30

H hold-to-run control 6 humidity 12 I I/O 22 I/O units 23 incremental jogging 19 inputs 22 installation 12 Interbus-S Slave 24, 35 interrupt 23 J jogging 19 joystick 8 L language 13 lighting connection 40 teach pendant 32 M mains supply 33 mains switch 33 mains voltage 33 maintenance 17 manipulator cable 39 mass memory 11 memory backup 11 extended 11 flash disk memory 11 mass storage 11 RAM memory 11 menu keys 7 mirroring 14

Product Specification S4Cplus M2000/BaseWare OS 4.0

41

Index

motion 17 motion keys 7 motion performance 17 Motion Supervision 20 Multitasking 23 N navigation keys 7 noise level 3 O operating mode 9 operating mode selector 9, 32 operating requirements 12 operation 7 operator dialogs 13 operator’s panel 9, 30 options 29 outputs 22 overspeed protection 6 P password 13, 15 performance 17 PLC functionality 23 position editing 14 execution 19 programming 14, 19 position fixed I/O 23 power supply 12 production window 15 Profibus DP Slave 24, 36 program editing 14 testing 15 programming 13 protection standards 12 Q QuickMove 17 R

S safeguarded space stop 6 delayed 6 safety 5 safety lamp 6 serial communication 27 service 17 service outlets 39, 40 signal data 24 singularity handling 20 Soft Servo 20 space requirements 3 standards 5 stationary TCP 19 stop point 14 structure 3 system signals 26 T TCP 19 teach pendant 7 cable 32 lighting 32 temperature 12 testing programs 15 transformer 33 trap routines 23 troubleshooting 17 TrueMove 18 U user-defined keys 8 V variants 29 volume 3 W window keys 7 windows 7 working space restricting 6

Rapid Language 16 reduced speed 5

42

Product Specification S4Cplus M2000/BaseWare OS 4.0

Product Specification IRB 140 3HAC 9041-1 / M2000

ABB Flexible Automation

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics AB. ABB Robotics AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics AB at its then current charge.

© ABB Robotics AB Article number: 3HAC 9041-1 Issue: M2000 ABB Robotics AB S-721 68 Västerås Sweden

Product Specification IRB 140 CONTENTS Page 1 Description ....................................................................................................................... 3 1.1 Structure.................................................................................................................. 3 1.2 Safety/Standards ..................................................................................................... 5 1.3 Installation .............................................................................................................. 7 Operating requirements.......................................................................................... 7 Mounting the manipulator...................................................................................... 7 Load diagram ......................................................................................................... 9 Mounting of equipment.......................................................................................... 11 1.4 Maintenance and Troubleshooting ......................................................................... 12 1.5 Robot Motion.......................................................................................................... 13 Velocity .................................................................................................................. 14 Resolution .............................................................................................................. 14 1.6 Signals .................................................................................................................... 14 Signal connections on robot arm............................................................................ 14 2 Specification of Variants and Options........................................................................... 15 3 Accessories ....................................................................................................................... 17 4 Index ................................................................................................................................. 19

Product Specification IRB 140 M2000

1

Product Specification IRB 140

2

Product Specification IRB 140 M2000

Description

1 Description 1.1 Structure IRB 140 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems. The robots with Foundry protection are designed for harsh environment and have special surface treatment and paint for excellent corrosion protection. The connectors are designed for severe environment, and bearings, gears and other sensitive parts are high protected. The high degree of tightness makes the robot steam washable. The Clean Room robots are classified for clean room class 10. They have the same degree of tightness and corrosion protection as the Foundry robots and are also steam washable. The robot is equipped with the operating system BaseWare OS. BaseWare OS controls every aspect of the robot, like motion control, development and execution of application programs communication etc. See Product Specification S4Cplus. For additional functionality, the robot can be equipped with optional software for application support - for example gluing and arc welding, communication features network communication - and advanced functions such as multitasking, sensor control etc. For a complete description on optional software, see the Product Specification RobotWare Options.

Axis 3 Axis 4 Axis 5

Axis 2 Axis 6

Axis 1

Figure 1 The IRB 140 manipulator has 6 axes.

Product Specification IRB 140 M2000

3

Description The IRB 140 is available in three different versions: - Standard IRB 140, for floor mounting, inverted mounting and wall mounting - IRB 140F, variants as above for foundry environment - IRB 140CR, variants as above for clean room environment. Weight:

Manipulator

98 kg (excluding the cables to the controller)

Airborne noise level: The sound pressure level outside the working space

< 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC) 595 380

65

70

360

810

352

175

201

273

70 448

CL

CL axis 1

R244 Minimum turning radius

123

402

Figure 2 View of the manipulator from the back, side and above (dimensions in mm).

4

Product Specification IRB 140 M2000

Description

1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.06/1992 Industrial robots, safety requirements ISO 9787 Manipulating industrial robots, coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC, Generic emission EN 50082-2 EMC, Generic immunity ISO 9409-1 Manipulating industrial robots, mechanical interface ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General Safety Requirements US Federal Standard 209 Clean room classification The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inches/min.). A speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot.

Product Specification IRB 140 M2000

5

Description Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate. Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Over-speed protection The speed of the robot is monitored by two independent computers. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. Safeguarded space stop The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at normal program stop with no deviation from the programmed path. After approx. one second the power supplied to the motors shuts off. Collision detection (option) In case an unexpected mechanical disturbance like a collision, electrode stik etc appears, the robot will stop and slightly back off from its stop position. Restricting the working space The movement of each of the axes can be restricted using software limits. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the key is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety. Safety lamp (option) The robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.

6

Product Specification IRB 140 M2000

Description

1.3 Installation There are three versions of IRB 140, one for normal industrial environment, one for foundry and one for clean room environment. An end effector, weighing a maximum of 5 kg, including payload, can be mounted on the robot’s mounting flange (axis 6). Other equipment, weighing a maximum of 1,5 kg, can be mounted on the upper arm. See page 11 for more information of mounting of extra equipment. Operating requirements Protection standards

IEC529

Standard manipulator Foundry manipulator Clean room manipulator

IP54 IP67 IP67

Clean room standards Clean room manipulator

US Federal Standard 209, class 10

Explosive environments The robot must not be located or operated in an explosive environment. Ambient temperature Manipulator during operation +5oC (41oF) to +45oC (113oF) Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF) for short periods (not exceeding 24 hours) up to +70oC (158oF) Relative humidity Complete robot during transportation and storage Max. 95% at constant temperature Complete robot during operation Max. 95% at constant temperature Mounting the manipulator Maximum load in relation to the base coordinate system. Endurance load in operation

Max. load at emergency stop

Force xy floor suspended wall

± 1300N ± 1300N ± 2200N

± 3200N ± 3200N ± 3900N

Force z

-1000 ± 1000N +1000 ±1 000N ± 1000N

-1000 ± 2000N +1000 ± 2000N ± 2200N

Torque Mxy

± 1300Nm

± 2200Nm

Torque Mz

± 300Nm

± 750Nm

floor suspended wall

Product Specification IRB 140 M2000

7

Description

∅ 13

39 1

∅ 25H8 (2x)

12

∅ 0,25

80

155

A

39

∅ 25H8 (2x)

45°

A

A-A

B-B

A

180

∅ 13

B

B

180

C Axis 1

A

Figure 3 Hole configuration (dimensions in mm).

8

Product Specification IRB 140 M2000

Description Load diagram The robot is optimized for the rated load according to the load diagram and rated moment of inertia. These have been used in the performance tests. The maximum allowed load and moment of inertia are received from the formulas on page 10. Load diagram "MIA" (Rated Performance)

Z mm

0,450 450

400 0,400

350 0,350 1kg

Z (m)

300 0,300

250 0,250 2kg

200 0,200

3kg

150 0,150 4kg 0,100 100

5kg

50 0,050

L mm 0,000 0

50 0,05

100 0,1

65

150 0,15

200 0,2

250 0,25

300 0,3

350 0,35

L (m)

Z = see the above diagram and the coordinate system in the Product Specification S4Cplus L = distance in X-Y plane from Z-axis to the centre of gravity J0 = rated own moment of inertia on the total handle weight = 0.012kgm2 Figure 4 Rated weight for tool mounted on the mounting flange at different positions (centres of gravity).

Product Specification IRB 140 M2000

9

Description Mass Length (Z, L) T J

kg m Nm kgm2

Mass ≤ 5 Kg Axis 5 Maximum static load: T5 = 9.81 • Mass • (Z+0.065)2 +L2 ≤ 8.5 Nm T5i = 9.81 • Mass • (Z +0.065 + L/1.04) ≤ 11.4 Nm Maximum dynamic load: J5 = Mass • ((Z+0.065)2 +L2) + max (J0L) ≤ 0.35 kgm2 Axis 6 Maximum static load: T6 = 9.81 • Mass • L

≤ 4.9 Nm

Maximum dynamic load: J6 = Mass • L2 + J0Z

≤ 0.24 kgm2

Z

X

Centre of gravity J0L = Maximum own moment of inertia around the maximum vector in the X-Y-plane J0Z = Maximum own moment of inertia around Z

Figure 5 Own moment of inertia.

10

Product Specification IRB 140 M2000

Description Mounting of equipment

51

70

62

74 37

31

Mounting holes for equipment M5 Depth 7.5 (2x)

Mounting holes for equipment M5 Depth 7.5 (2x) Note! Maximum 0.5 kg if 1.0 kg on the upper arm house

D=150

0 kg if 1,5 kg on the upper arm house

185 120 D=220 Note! Maximum 1 kg if 0,5 kg on the wrist 1,5 kg if 0 kg on the wrist Figure 6 The shaded area indicates the permitted position of the centre of gravity for any extra equipment mounted (dimensions in mm).

A o

D=6

45

+0.012 -0 H7

∅ 0.05

B

B

9

h8 +0 -0.039

D=25 -0

+0.033

R=20

D=50

H8

M6 (4x)

A 90o (4x) 6

A-A Figure 7 The mechanical interface, mounting flange (dimensions in mm).

Product Specification IRB 140 M2000

11

Description 1.4 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - Maintenance-free AC motors are used. - Oil is used for all gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change. - It has a program memory “battery low” alarm. The following maintenance is required: - Changing batteries every third year. The maintenance intervals depends on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.

12

Product Specification IRB 140 M2000

Description 1.5 Robot Motion Type of motion Axis 1 Rotation motion Axis 2 Arm motion Axis 3 Arm motion Axis 4 Wrist motion

Range of movement _ +180o -180o _ o +110 -90o _ -230o +50o _ o +200 -200o Default +165 revolutions _ -165 revolutions Max**) _ -120o +120o _ +400o -400o Default +163 revolutions _ -163 revolutions Max**)

Axis 5 Bend motion Axis 6 Turn motion

**) Option. The default working range for axis 4 and axis 6 can be extended by changing parameter values in the software Pos 1

Z Pos 0

Pos 6 Pos 7

1120

1243

Pos 2

Pos 8

Pos 3

X 151

28

70 184 670

486

324 810

Positions at wrist centre (mm) x z pos. 0 450 712 1 70 1092 2 314 421 3 765 99 6 1 596 7 218 558 8 -670 352

Angle (degrees) pos. axis 2 axis 3 0 0 0 1 0 -90 2 0 +50 3 110 -90 6 -90 +50 7 110 -230 8 -90 -90

Figure 8 The extreme positions of the robot arm.

Product Specification IRB 140 M2000

13

Description Velocity Axis no. 1 2 3 4 5 6

200o/s 200o/s 260o/s 360o/s 360o/s 450o/s

There is a supervision to prevent overheating in applications with intensive and frequent movements. Resolution Approx. 0.01o on each axis.

1.6 Signals Signal connections on robot arm For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling from the controller to the upper arm housing. In the controller, the signals are connected to 12-pole terminals, Phoenix MSTB 2.5/12ST-5.08, and on the upper arm housing to FCI UT07 14 12SH44N. Hose for compressed air is also integrated into the manipulator. There is an inlet (R1/4”) at the base and an outlet (R1/4”) on the upper arm housing. Signals Air

14

12 1

49V, 500 mA Max. 8 bar, inner hose diameter 6.5 mm

Product Specification IRB 140 M2000

Specification of Variants and Options

2 Specification of Variants and Options The different variants and options for the IRB 140 are described below. The same numbers are used here as in the Specification form. For controller options, see Product Specification S4Cplus, and for software options, see Product Specification RobotWare Options.

1 MANIPULATOR VARIANTS 021 IRB 140 / IRB 140F / IRB 140CR Manipulator colour 330 ABB orange 331- Colours according to RAL-codes. 348 353 ABB orange foundry Protection 035 Standard manipulator 036 Foundry Robot adapted for foundry environments. Degree of protection as in Chapter 1.3. The manipulator is specially painted and finished. Only available colour is ABB orange Foundry. 037 Clean Room Robot with clean room class 10 and with the same protection as in option 036. Only available colour is white.

EQUIPMENT 691 Safety lamp A safety lamp with an orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode. The safety lamp is required on a UL/UR approved robot.

Product Specification IRB 140 M2000

15

Specification of Variants and Options

16

Product Specification IRB 140 M2000

Accessories

3 Accessories Basic software and software options for robot and PC For more information, see Product Specification S4Cplus, and Product Specification RobotWare Options. Robot Peripherals - Motor Units

Product Specification IRB 140 M2000

17

Accessories

18

Product Specification IRB 140 M2000

Index

4 Index

O

A accessories 17

operating requirements 7 options 15 overspeed protection 6

C

P

clean room standards 7 cooling device 4

payload 7 protection standards 7

E

R

emergency stop 6 enabling device 6 equipment mounting 11 permitted extra load 11

range of movement working space 13 reduced speed 5 resolution 14 Robot Peripherals 17 robot versions 4, 15

F fire safety 6 H hold-to-run control 6 hole configuration 8 humidity 7 I

S safeguarded space stop 6 delayed 6 safety 5 safety lamp 6, 15 service 12 space requirements 4 standards 5 structure 3

installation 7 T L load 7 load diagrams 9

temperature 7 troubleshooting 12 U

M UL approved 5 maintenance 12 mechanical interface 11 motion 13 mounting extra equipment 11 robot 7 mounting flange 11 N noise level 4

Product Specification IRB 140 M2000

V variants 4, 15 velocity 14 W weight 4 working space restricting 6

19

Index

20

Product Specification IRB 140 M2000

Product Specification RobotWare Options 3HAC 9218-1 / BaseWare OS 4.0

ABB Flexible Automation

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics AB. ABB Robotics AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics AB at its then current charge.

© ABB Robotics AB Article number: 3HAC 9218-1 Issue: BaseWare OS 4.0 ABB Robotics AB S-721 68 Västerås Sweden

Product Specification RobotWare Options CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 BaseWare Options ........................................................................................................... 5 2.1 Advanced Functions ............................................................................................... 5 2.2 Advanced Motion ................................................................................................... 9 2.3 Multitasking............................................................................................................ 12 2.4 FactoryWare Interface ............................................................................................ 13 2.5 RAP Communication.............................................................................................. 15 2.6 Ethernet Services .................................................................................................... 16 2.7 Profibus DP............................................................................................................. 17 2.8 Interbus-S................................................................................................................ 18 2.9 Load Identification and Collision Detection (LidCode)......................................... 19 2.10 ScreenViewer........................................................................................................ 20 2.11 Conveyor Tracking ............................................................................................... 22 2.12 I/O Plus ................................................................................................................. 23 2.13 Developer’s Function ........................................................................................... 24 3 ProcessWare..................................................................................................................... 27 3.1 ArcWare.................................................................................................................. 27 3.2 ArcWare Plus ......................................................................................................... 30 3.3 SpotWare................................................................................................................ 31 3.4 SpotWare Plus......................................................................................................... 34 3.5 DispenseWare ........................................................................................................ 35 3.6 PaintWare................................................................................................................ 37 3.7 PalletWare............................................................................................................... 39 4 Index ................................................................................................................................. 43

Product Specification RobotWare Options for BaseWare OS 4.0

1

Product Specification RobotWare Options

2

Product Specification RobotWare Options for BaseWare OS 4.0

Introduction

1 Introduction RobotWare is a family of software products from ABB Flexible Automation designed to make you more productive and lower your cost of owning and operating a robot. ABB Flexible Automation has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations. Within the RobotWare family there are three classes of products: BaseWare OS - This is the operating system of the robot and constitutes the kernel of the RobotWare family. BaseWare OS provides all the necessary features for fundamental robot programming and operation. It is an inherent part of the robot but can be provided separately for upgrading purposes. For the description of BaseWare OS, see Product Specification S4Cplus. BaseWare Options - These products are options that run on top of BaseWare OS of the robot. They represent functionality for robot users that need additional functionality, for example run multitasking, transfer information from file to robot, communicate with a PC, perform advanced motion tasks etc. ProcessWare - ProcessWare products are designed for specific process applications like welding, gluing and painting. They are primarily designed to improve the process result and to simplify installation and programming of applications. These products also run on top of BaseWare OS.

Product Specification RobotWare Options for BaseWare OS 4.0

3

Introduction

4

Product Specification RobotWare Options for BaseWare OS 4.0

Advanced Functions

2 BaseWare Options 2.1 Advanced Functions Includes functions making the following possible: - Information transfer via serial channels or files. - Setting an output at a specific position. - Executing a routine at a specific position. - Defining forbidden areas within the robot´s working space. - Automatic setting of output when the robot is in a user-defined area. - Robot motion in an error handler or trap routine, e.g. during automatic error handling. - Cross connections with logical conditions. - Interrupts from analog input or output signals. Transferring information via serial channels Data in the form of character strings, numeric values or binary information can be transferred between the robot and other peripheral equipment, e.g. a PC, bar code reader, or another robot. Information is transferred via an RS232 or RS485 serial channel. Examples of applications: - Printout of production statistics on a printer connected to the robot. - Reading part numbers from a bar code reader with a serial interface. - Transferring data between the robot and a PC. The transfer is controlled entirely from the robot’s work program. When it is required to control the transfer from a PC, use the option RAP Communication or FactoryWare Interface. Data transfer via files Data in the form of character strings, numerical values or binary information can be written to or read from files on a diskette or other type of mass storage/memory. Examples of applications: - Storing production statistics on a diskette or ramdisk. This information can then be read and processed by an ordinary PC. - The robot’s production is controlled by a file. This file may have been created in a PC, stored on a diskette, and read by the robot at a later time. Product Specification RobotWare Options for BaseWare OS 4.0

5

Advanced Functions Fixed position output The value of an output (digital, analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. The output will then change at the same place every time, irrespective of the robot’s speed. Consideration can also be given to time delays in the process equipment. By specifying this time delay (max. 500 ms), the output is set at the corresponding time before the robot reaches the specified position. The distance can also be specified as a certain time before the programmed position. This time must be within the deceleration time when approaching that position. Examples of applications: - Handling press work, to provide a safe signalling system between the robot and the press, which will reduce cycle times. Just as the robot leaves the press, an output is set that starts the press. - Starting and finishing process equipment. When using this function, the start will always occur at the same position irrespective of the speed. For gluing and sealing, see GlueWare. Fixed position procedure call A procedure call can be carried out when the robot passes the middle of a corner zone. The position will remain the same, irrespective of the robot’s speed. Example of application: - In the press example above, it may be necessary to check a number of logical conditions before setting the output that starts the press. A procedure which takes care of the complete press start operation is called at a position just outside the press. World Zones A spherical, cylindrical or cubical volume can be defined within the working space. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”, both during program execution and when the robot is jogged into this area. The areas, which are defined in the world coordinate system, can be automatically activated at start-up or activated/deactivated from within the program. Examples of applications: - A volume is defining the home position of the robot. When the robot is started from a PLC, the PLC will check that the robot is inside the home volume, i.e. the corresponding output is set. - The volume is defining where peripheral equipment is located within the working space of the robot.

6

Product Specification RobotWare Options for BaseWare OS 4.0

Advanced Functions This ensures that the robot cannot be moved into this volume. - A robot is working inside a box. By defining the outside of the box as a forbidden area, the robot cannot run into the walls of the box. - Handshaking between two robots both working in the same working space. When one of the robots enters the common working space, it sets an output and after that enters only when the corresponding output from the other robot is reset. Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one. The robot stores information about the original movement path which allows it to be resumed later. Examples of applications: - Cleaning the welding gun when a welding fault occurs. When a welding fault occurs, there is normally a jump to the program’s error handler. The welding movement in progress can be stored and the robot is ordered to the cleaning position so that the nozzle can be cleaned. The welding process can then be restarted, with the correct parameters, at the position where the welding fault occurred. This is all automatic, without any need to call the operator. (This requires options ArcWare or ArcWare Plus.) - Via an input, the robot can be ordered to interrupt program execution and go to a service position, for example. When program execution is later restarted (manually or automatically) the robot resumes the interrupted movement. Cross-connections with logical conditions Logical conditions for digital input and output signals can be defined in the robot’s system parameters using AND, OR and NOT. Functionality similar to that of a PLC can be obtained in this way. Example: - Output 1 = Input 2 AND Output 5. - Input 3 = Output 7 OR NOT Output 8. Examples of applications: - Program execution to be interrupted when both inputs 3 and 4 become high. - A register is to be incremented when input 5 is set, but only when output 5=1 and input 3=0. Interrupts from analog input or output signals An interrupt can be generated if an analog input (or output) signal falls within or outside a specified interval. Product Specification RobotWare Options for BaseWare OS 4.0

7

Advanced Functions RAPID instructions and functions included in this option Open Close Write WriteBin WriteStrBin ReadNum ReadStr ReadBin Rewind WriteAnyBin ReadAnyBin ReadStrBin ClearIOBuff WZBoxDef WZCylDef WZLimSup WZSphDef WZDOSet WZDisable WZEnable WZFree StorePath RestoPath TriggC TriggL TriggJ TriggIO TriggEquip TriggInt MoveCSync MoveLSync MoveJSync ISignalAI ISignalAO

8

Opens a file or serial channel Closes a file or serial channel Writes to a character-based file or serial channel Writes to a binary file or serial channel Writes a string to a binary serial channel Reads a number from a file or serial channel Reads a string from a file or serial channel Reads from a binary file or serial channel Rewind file position Write data to a binary serial channel or file Read data from a binary serial channel or file Read a string from a binary serial channel or file Clear input buffer of a serial channel Define a box shaped world zone Define a cylinder shaped world zone Activate world zone limit supervision Define a sphere shaped world zone Activate world zone to set digital output Deactivate world zone supervision Activate world zone supervision Erase world zone supervision Stores the path when an interrupt or error occurs Restores the path after an interrupt/error Position fix output/interrupt during circular movement Position fix output/interrupt during linear movement Position fix output/interrupt during joint movement Definition of trigger conditions for one output Definition of trigger conditions for process equipment with time delay Definition of trigger conditions for an interrupt Position fix procedure call during circular movement Position fix procedure call during linear movement Position fix procedure call during joint movement Interrupts from analog input signal Interrupts from analog output signal

Product Specification RobotWare Options for BaseWare OS 4.0

Advanced Motion 2.2 Advanced Motion Contains functions that offer the following possibilities: - Resetting the work area for an axis. - Independent movements. - Contour tracking. - Coordinated motion with external manipulators. Resetting the work area for an axis The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements. Examples of applications: - When polishing, a large work area is sometimes needed on the robot axis 4 or axis 6 in order to be able to carry out final polishing without stopping. Assume that the axis has rotated 3 turns, for example. It can now be reset using this function, without having to physically rotate it back again. Obviously this will reduce cycle times. - When arc welding, the work object is often fitted to a rotating external axis. If this axis is rotated more than one turn during welding, the cycle time can be reduced because it is not necessary to rotate the axis back between welding cycles. Coordinated motion with multi-axis manipulators Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires the Advanced Motion option. Note that simultaneous coordination with several single axis manipulators, e.g. track motion and workpiece manipulator, does not require Advanced Motion. Note! There is a built-in general method for defining the geometry for a manipulator comprising two rotating axes (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest ABB Flexible Automation Centre. Contour tracking Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion. Example of application: - A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted. Product Specification RobotWare Options for BaseWare OS 4.0

9

Advanced Motion Independent movements A linear or rotating axis can be run independently of the other axes in the robot system. The independent movement can be programmed as an absolute or relative position. A continuous movement with a specific speed can also be programmed. Examples of applications: - A robot is working with two different stations (external axes). First, a work object located at station 1 is welded. When this operation is completed, station 1 is moved to a position where it is easy to change the work object and at the same time the robot welds the work object at station 2. Station 1 is moved independently of the robot’s movement, which simplifies programming and reduces the cycle time. - The work object is located on an external axis that rotates continuously at a constant speed. In the mean time, the robot sprays plasma, for example, on the work object. When this is finished the work area is reset for the external axis in order to shorten the cycle time. Friction Compensation During low speed (10-100 mm/s) cutting of fine profiles, in particular small circles, a friction effect, typically in the form of approximately 0.5 mm “bumps”, can be noted. Advanced Motion offers a possibility of compensating for these frictional effects. Typically a 0.5 mm “bump” can be reduced to about 0.1 mm. This, however, requires careful tuning of the friction level (see User’s Guide for tuning procedure). Note that even with careful tuning, there is no guarantee that “perfect” paths can always be generated. For the IRB 6400 family of robots, no significant effects can be expected by applying Friction Compensation. External Drive System With Advanced Motion, the possibility to connect off-the-shelf standard drive systems for controlling external axes is available. This can be of interest, for example, when the power of the available S4C drives does not match the requirements. There are two alternatives: - The Atlas Copco Controls´ stand alone servo amplifier DMC. - The Atlas Copco Controls´ FBU (Field Bus Unit) that can handle up to three external drive units per FBU unit. These can be connected to analog outputs (+/- 10 V) or a field bus. The drive board can thus be of virtually any make and type. For further information about DMC and FBU, please contact Atlas Copco Controls. NOTE! The DMC/FBU must be equipped with Atlas Copco Controls option C.

10

Product Specification RobotWare Options for BaseWare OS 4.0

Advanced Motion RAPID instructions and functions included in this option IndReset IndAMove IndDMove IndRMove IndCMove IndInpos IndSpeed CorrCon CorrWrite CorrRead CorrDiscon CorrClear

Resetting the work area for an axis Running an axis independently to an absolute position Running an axis independently for a specified distance Running an axis independently to a position within one revolution, without taking into consideration the number of turns the axis had rotated earlier Running an axis continuously in independent mode Checking whether or not an independent axis has reached the programmed position Checking whether or not an independent axis has reached the programmed speed Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators

Product Specification RobotWare Options for BaseWare OS 4.0

11

Multitasking

2.3 Multitasking Up to 10 programs (tasks) can be executed in parallel with the normal robot program. - These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode. - They are programmed using standard RAPID instructions, except for motion instructions. - They can be programmed to carry out various activities in manual or automatic mode, and depending on whether or not the main process is running. - Communication between tasks is carried out via I/O or global data. - Priorities can be set between the processes. Examples of applications: - The robot is continuously monitoring certain signals even when the robot program has stopped, thus taking over the job traditionally allocated to a PLC. - An operator dialogue is required at the same time as the robot is doing, for example, welding. By putting this operator dialogue into a background task, the operator can specify input data for the next work cycle without having to stop the robot. - The robot is controlling a piece of external equipment in parallel with the normal program execution. Performance When the various processes are programmed in the correct way, no performance problems will normally occur: - When the priorities for the various processes are correctly set, the normal program execution of the robot will not be affected. - Because monitoring is implemented via interrupts (instead of checking conditions at regular intervals), processor time is required only when something actually happens. - All input and output signals are accessible for each process. Note that the response time of Multitasking does not match that of a PLC. Multitasking is primary intended for less demanding tasks. The available program memory can be divided up arbitrarily between the processes. However, each process in addition to the main process will reduce the total memory, see Product Specification S4Cplus.

12

Product Specification RobotWare Options for BaseWare OS 4.0

FactoryWare Interface

2.4 FactoryWare Interface This option enables the robot system to communicate with a PC using RobComm 3.0 or later versions (see FactoryWare). The FactoryWare Interface 3.2 serves as a runtime license for RobComm, i.e. the PC does not require any license protection when executing a RobComm based application. However, when developing such an application, a hardware lock and password are needed in the PC (design time license). Older versions of RobComm will require RAP Communication in the robot and license protection in the PC (hardware lock and password for design and run-time, or only password for only run-time). This option will also work with RobView 3.2/1 or DDE Server 2.3/1 (or later versions). Older versions work only with RAP Communication. In all cases RobView and DDE Server will require the hardware lock and password. The Factory Ware Interface 3.2 includes the Robot Application Protocol (RAP), based on MMS functionality. The Robot Application Protocol is used for computer communication. The following functions are supported: - Start and stop program execution - Transfer programs to/from the robot - Transfer system parameters to/from the robot - Transfer files to/from the robot - Read the robot status - Read and write data - Read and write output signals - Read input signals - Read error messages - Change robot mode - Read logs RAP communication is available both for serial links and network, as illustrated by the figure below. RAP RPC (Remote Procedure Call) TCP/IP Standard protocols SLIP

Ethernet

RS232/RS422

Product Specification RobotWare Options for BaseWare OS 4.0

13

FactoryWare Interface Examples of applications: - Production is controlled from a superior computer. Information about the robot status is displayed by the computer. Program execution is started and stopped from the computer, etc. - Transferring programs and parameters between the robot and a PC. When many different programs are used in the robot, the computer helps in keeping track of them and by doing back-ups. - Programs can be transferred to the robot’s ramdisk at the same time as the robot executes its normal program. When execution of this program has finished, the new program can be read very quickly from the ramdisk and program execution can continue. In this way a large number of programs can be handled and the robot’s memory does not have to be so big. RAPID instruction included in this option SCWrite

14

Sends a message to the computer (using RAP)

Product Specification RobotWare Options for BaseWare OS 4.0

RAP Communication

2.5 RAP Communication This option is required for all communication with a superior computer, where none of the FactoryWare products RobComm, RobView, or DDE Server, are used. It includes the same functionality described for the option Factory Ware Interface. It also works for the FactoryWare products. For RobView and DDE Server, there is no difference from the FactoryWare Interface (except that the price is higher). For RobComm, in this case a license protection requirement in the PC is added. Note that both FactoryWare Interface and RAP Communication can be installed simultaneously.

Product Specification RobotWare Options for BaseWare OS 4.0

15

Ethernet Services

2.6 Ethernet Services NFS Information in mass storage, e.g. the hard disk in a PC, can be read directly from the robot using the NFS protocol. The robot control program can also be booted via Ethernet instead of using diskettes. This requires Ethernet hardware in the robot. FTP This option includes the same functionality as described for Ethernet Services NFS exept that the protocol used for remote mounted disc functionality is FTP. The aspect of authorization differs between NFS and FTP. Examples of applications: - All programs for the robot are stored in the PC. When a new part is to be produced, i.e. a new program is to be loaded, the program can be read directly from the hard disk of the PC. This is done by a manual command from the teach pendant or an instruction in the program. If the option RAP Communication or FactoryWare Interface is used, it can also be done by a command from the PC (without using the ramdisk as intermediate storage). - Several robots are connected to a PC via Ethernet. The control program and the user programs for all the robots are stored on the PC. A software update or a program backup can easily be executed from the PC.

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Product Specification RobotWare Options for BaseWare OS 4.0

Profibus DP

2.7 Profibus DP With a Profibus-DP Master/Slave board (DSQC368) in the S4C controller it is possible to connect many sets of in- and output I/O units via the serial Profibus-DP field bus net, and all the Profibus-DP signals are handled and addressed in the same way as any other distributed I/O signal. The maximum number of I/O units that can be defined in the S4C system is described in User’s Guide Baseware chapter I/O data specification. As I/O units counts all DPslave units connected to the S4C DP-master, the DP-slave, simulated I/O units and other I/O units connected to other S4C fieldbuses. It is possible to connect digital and/or analog in- and output I/O units on the DSQC368 master bus. All I/O units must fulfil the DIN 19245 Part 3 Profibus Specification - DP and must be certified by PNO1.

1. Profibus Nutzer Organization

Product Specification RobotWare Options for BaseWare OS 4.0

17

Interbus-S

2.8 Interbus-S With an InterBus-S generation 4 Master/Slave board (DSQC344) in the S4C robot controller, it is possible to connect many sets of input/output modules via the serial InterBus-S field bus net. The robot controller handles and addresses the InterBus-S I/O signals in the same way it manages any other S4C distributed I/O signals. It should be noted that this is a supplementary manual to the other robot manuals. Detailed description of the InterBus-S and different I/O units will be found in the documents from e.g. Phoenix Contact & Co.

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Product Specification RobotWare Options for BaseWare OS 4.0

Load Identification and Collision Detection (LidCode)

2.9 Load Identification and Collision Detection (LidCode) This option is available for the following robot families: IRB 140, IRB 1400, IRB 2400, IRB 4400, IRB 6400 and for external manipulators IRBP-L and IRBP-K. LidCode contains two very useful features: Load Identification To manually calculate or measure the load parameters accurately can be very difficult and time consuming. Operating a robot with inaccurate load parameters can have a detrimental influence on cycle time and path accuracy. With LidCode, the robot can carry out accurate identification of the complete load data (mass, centre of gravity, and three inertia components). If applicable, tool load and payload are handled separately. The identification procedure consists of limited predefined movements of axes 3, 5 and 6 during approximately three minutes. The starting point of the identification motion pattern can be chosen by the user so that collisions are avoided. The accuracy achieved is normally better than 5%. Collision Detection Abnormal torque levels on any robot axis (not external axes) are detected and will cause the robot to stop quickly and thereafter back off to relieve forces between the robot and environment. Tuning is normally not required, but the sensitivity can be changed from Rapid or manually (the supervision can even be switched off completely). This may be necessary when strong process forces are acting on the robot. The sensitivity (with default tuning) is comparable to the mechanical alternative (mechanical clutch) and in most cases much better. In addition, LidCode has the advantages of no added stick-out and weight, no need for connection to the e-stop circuit, no wear, the automatic backing off after collision and, finally, the adjustable tuning. Two system outputs reflect the activation and the trig status of the function. RAPID instructions included in this option MotionSup ParldRobValid ParldPosValid LoadId MechUnitLoad

Changing the sensitivity of the collision detection or activating/deactivating the function. Checking that identification is available for a specific robot type. Checking that the current position is OK for identification. Performing identification. Defenition of payload for external mechanical units.

Product Specification RobotWare Options for BaseWare OS 4.0

19

ScreenViewer

2.10 ScreenViewer This option adds a user window to display user defined screens with advanced display functions. The user window can be displayed at any time, regardless of the execution state of the RAPID programs. User defined screens The user defined screens are composed of: • A fixed background with a size of 12 lines of 40 characters each. These characters can be ASCII and/or horizontal or vertical strokes (for underlining, separating or framing). • 1 to 5 function keys. • 1 to 4 pop-up menus containing from 1 to 10 choices. • 1 to 30 display and input fields defined by: - Their position and size. - Their type (display, input). - Their display format (integer, decimal, binary, hexadecimal, text). - A possible boundary with minimum and maximum limits. Example of a user defined screen. The ### represent the fields. SpotTim Program number: ###

PHASES SQUEEZE PREHEAT COOLING ## HEAT COLD LASTCOLD POSTHEAT HOLD Next

View

File

| | | | | | | | |

XT ## ## ## ## ## ## ## ##

| | | | | | | | | |

CURENT (A) START | END | #### | | #### #### | | | #### | #### | Prev.

(Copy)

Heat stepper: ### interpolated: ## | | Tolerance: ###% | Force: ###daN | Forge: ###daN | | Fire chck: ### | | Err allow: ###% | Numb err: ###

Valid

Advanced Display functions The user defined screens run independently of the RAPID programs. Some events occur on a screen (new screen displayed, menu choice selected, function key pressed, field modified, ...). A list of user screen commands can be associated with any of these events, then when the event occurs, the command list will be executed.

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Product Specification RobotWare Options for BaseWare OS 4.0

ScreenViewer A screen event can occur - When a new screen is displayed (to initialize the screen contents). - After a chosen interval (to refresh a screen). - When a menu choice or a function key is selected (to execute a specific action, or change the screen). - When a new value is entered in a field, or when a new field is selected (to execute some specific action). The commands that can be executed on screen events are - Reading/writing RAPID or I/O data. - Reading/writing fields contents. - Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the data read. - Comparing data read (=, <, >) and carrying out a command or not, depending on the comparison result. - Displaying a different screen. Capacities The user screens can be grouped in a screen package file under a specific name. Up to 8 packages can be loaded at the same time. A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen packages. - The screen package to be displayed is selected using the far right hand menu “View” (which shows a list of the screen packages installed).

Product Specification RobotWare Options for BaseWare OS 4.0

21

Conveyor Tracking

2.11 Conveyor Tracking Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor. While tracking the conveyor, the programmed TCP speed relative to the work object will be maintained, even when the conveyor speed is changing slowly. Note that hardware components for measuring the conveyor position are also necessary for this function. Please refer to the Product Specification for your robot. Conveyor Tracking provides the following features: - A conveyor can be defined as either linear or circular. - It is possible to have two conveyors connected simultaneously and to switch between tracking the one or the other. - Up to 254 objects can reside in an object queue which can be manipulated by RAPID instructions. - It is possible to define a start window in which an object must be before tracking can start. - A maximum tracking distance may be specified. - If the robot is mounted on a parallel track motion, then the system can be configured such that the track will follow the conveyor and maintain the relative position to the conveyor. - Tracking of a conveyor can be activated “on the fly”, i.e. it is not necessary to stop in a fine point. Performance At 150 mm/s constant conveyor speed, the TCP will stay within +/-2 mm of the path as seen with no conveyor motion. When the robot is stationary relative to the conveyor, the TCP will remain within 0.7 mm of the intended position. These values are valid as long as the robot is within its dynamic limits with the added conveyor motion and they require accurate conveyor calibration. RAPID instructions included in this option WaitWObj DropWObj

22

Connects to a work object in the start window Disconnects from the current object

Product Specification RobotWare Options for BaseWare OS 4.0

I/O Plus

2.12 I/O Plus I/O Plus enables the S4C to use non-ABB I/O units. The following units are supported: - Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3. - Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2 (16 digital input signals). - Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1 (8 digital input signals and 8 digital output signals). For more information on any of these untis, please contact the supplier. The communication between these units and S4C has been verified (this does not, however, guarantee the internal functionality and quality of the units). Configuration data for the units is included. In I/O Plus there is also support for a so-called “Welder”. This is a project specific spot welding timer, and is not intended for general use. In addition to the above units, the I/O Plus option also opens up the possibility to use other digital I/O units that conform with the DeviceNet specification. ABB Robotics AB does not assume any responsibility for the functionality or quality of such units. The user must provide the appropriate configuration data.

Product Specification RobotWare Options for BaseWare OS 4.0

23

Developer’s Function

2.13 Developer’s Function This option is intended to be used by application developers requiring more advanced functions than normally available for an end user. The package includes a detailed reference manual on the RAPID language kernel and a number of instruction and function groups useful for different application development as listed below. The groups are: - Bit Functions - Data Search Functions - RAPID Support Functions - Power Failure Functions - Trigg Functions - File Operation Functions RAPID Kernel Reference Manual The manual describes the RAPID language syntax and semantics in detail concerning the kernel, i.e. all general language elements which are not used to control robot or other equipment. In addition to this the manual includes descriptions on: - Built-in Routines - Built-in Data Objects - Built-in Objects - Intertask Objects - Text Files - Storage allocation for RAPID objects Bit Functions This is a package for handling, i.e. setting, reading and clearing, individual bits in a byte. The instructions/functions are: byte BitSet BitClear BitCheck BitAnd BitOr BitXOr BitNeg BitLSh BitRSh 24

Data type for a byte data Set a specified bit in a byte Clear a specified bit in a byte Check if a specified bit in a byte is set Logical bitwise AND operation on byte Logical bitwise OR operation on byte Logical bitwise XOR operation on byte Logical bitwise NEGATION operation on byte Logical bitwise LEFT SHIFT operation on byte Logical bitwise RIGHT SHIFT operation on byte Product Specification RobotWare Options for BaseWare OS 4.0

Developer’s Function Data Search Functions With these functions it is possible to search all data in a RAPID program, where the name or the data type is given as a text string. This might be useful for instance in the following examples: - A common problem is to check if a data with a certain name is declared in the system, and in such case what is its value, e.g.a robtarget - Another problem is to list all variables of a certain datatype, which are declared in the system, and write their values on the screen, e.g. all weld data. The following instructions/functions are included in the package: SetDataSearch

Define the search criteria

GetNextSym

Search next data and get its name as a string

GetDataVal

Get the value of a data, specified with a string for the name

SetDataVal

Set the value of a data, specified with a string for the name

RAPID Support Functions This package includes a number of miscellaneous instructions etc., which are used in application development. User defined data types

This will make it possible to create your own data types, like a record definition

AliasIO

Instruction used to define a signal of any type with an alias (alternative) name. The instruction can be used to make generic modules work together with site specific I/O, without changing the program code.

ArgName

Function used inside a routine to get the name of a data object, which is referenced as argument in the call of the routine. The name is given as a string. The function can also be used to convert the identifier of a data into a string.

BookErrNo

Instruction used to book a new RAPID system error number. This should be used to avoid error number conflicts if different generic modules are combined in a system.

TextTabGet

Function used to get the text table number of a user defined text table during runtime.

TextGet

Function used to get a text string from the system text tables (installed at cold start).

IsSysId

Function used to test the system identity.

SetSysData

Instruction which will activates the specified system data (tool or workobject). With this instruction it is possible to change the current active tool or workobject.

IsStopStateEvent

Function which will return information about the movement of the Program Pointer (PP).

Product Specification RobotWare Options for BaseWare OS 4.0

25

Developer’s Function ReadCfgData

Read system configuration data.

WriteCfgData

Write system configuration data.

Power Failure Functions The package is used to get I/O signal values before power failure and to reset them at power on. The following instructions are included and are normally used in the power on event routine: PFIOResto

Restore the values of all digital output signals.

PFDOVal

Get the value of the specified digital output signal at the time for power failure.

PFGOVal

Get the value of the specified digital output group at the time for power failure.

PFRestart

Check if path has been interrupted.

Trigg Functions TriggSpeed

Instruction to define conditions and actions for control of an analog output signal with an output value proportional to the actual TCP speed.

StepBwdPath

Instruction used to move backward on its path in a RESTART event routine.

TriggStopProc

Generation of restart data at program stop or emergency stop.

File Operation Functions The package includes instructions and functions to work with directories and files on mass memory like floppy disc, flash disc or hard disc. It can be used when creating application packages, using RAPID, where RAPID programs and modules should be loaded or stored. It can also be used to search for all files in different directories and e.g. list them on the teach pendant. The following instructions and functions are available:

26

dir

Datatype for variables referencing a directory

MakeDir

Create a new directory

OpenDir

Open a directory to read the underlaying files or subdirectories

CloseDir

Close a directory

RemoveDir

Delete a directory

ReadDir

Read next object in a directory, file or subdirectory

RemoveFile

Delete a file

IsFile

Check the type of a file

FileSize

Get the size of a file

FSSize

Get the size of a file system Product Specification RobotWare Options for BaseWare OS 4.0

ArcWare

3 ProcessWare 3.1 ArcWare ArcWare comprises a large number of dedicated arc welding functions, which make the robot well suited for arc welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. ArcWare functions A few examples of some useful functions are given below. Adaptation to different equipment The robot can handle different types of weld controllers and other welding equipment. Normally communication with the welding controller uses parallel signals but a serial interface is also available. Advanced process control Voltage, wire feed rate, and other process data can be controlled individually for each weld or part of a weld. The process data can be changed at the start and finish of a welding process in such a way that the best process result is achieved. Testing the program When testing a program, welding, weaving or weld guiding can all be blocked. This provides a way of testing the robot program without having the welding equipment connected. Automatic weld retry A function that can be configured to order one or more automatic weld retries after a process fault. Weaving The robot can implement a number of different weaving patterns up to 10 Hz depending on robot type. These can be used to fill the weld properly and in the best possible way. Weaving movement can also be ordered at the start of the weld in order to facilitate the initial striking of the arc.

Product Specification RobotWare Options for BaseWare OS 4.0

27

ArcWare Wire burnback and rollback These are functions used to prevent the welding wire sticking to the work object. Fine adjustment during program execution The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst welding is in progress. This makes trimming of the process much easier because the result can be seen immediately on the current weld. This can be done in both manual and automatic mode. Weld Guiding Weld guiding can be implemented using a number of different types of sensors. Please contact your nearest ABB Flexible Automation Centre for more information. Interface signals The following process signals are, if installed, handled automatically by ArcWare. The robot can also support dedicated signals for workpiece manipulators and sensors.

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Digital outputs Power on/off Gas on/off Wire feed on/off Wire feed direction Weld error Error information Weld program number

Description Turns weld on or off Turns gas on or off Turns wire feed on or off Feeds wire forward/backward Weld error Digital outputs for error identification Parallel port for selection of program number, or 3-bit pulse port for selection of program number, or Serial CAN/Devicenet communication

Digital inputs Arc OK Voltage OK Current OK Water OK Gas OK Wire feed OK Manual wire feed Weld inhibit Weave inhibit Stop process Wirestick error Supervision inhibit Torch collision

Description Arc established; starts weld motion Weld voltage supervision Weld current supervision Water supply supervision Gas supply supervision Wire supply supervision Manual command for wire feed Blocks the welding process Blocks the weaving process Stops/inhibits execution of arc welding instructions Wirestick supervision Program execution without supervision Torch collision supervision

Analog outputs Voltage Wire feed Current Voltage adjustment Current adjustment

Description Weld voltage Velocity of wire feed Weld current Voltage synergic line amplification Current synergic line amplification Product Specification RobotWare Options for BaseWare OS 4.0

ArcWare Analog inputs (cont.)

Description (cont.)

Voltage

Weld voltage measurement for monitoring and supervision Weld current measurement for monitoring and supervision

Current

RAPID instructions included in this option ArcL ArcC ArcKill ArcRefresh

Arc welding with linear movement Arc welding with circular movement Aborts the process and is intended to be used in error handlers Updates the weld references to new values

Product Specification RobotWare Options for BaseWare OS 4.0

29

ArcWare Plus

3.2 ArcWare Plus ArcWare Plus contains the following functionality: - ArcWare, see previous chapter. - Arc data monitoring. Arc data monitoring with adapted RAPID instructions for process supervision. The function predicts weld errors. - Contour tracking. Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion. Example of application: A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted. - Adaptive process control. Adaptive process control for LaserTrak and Serial Weld Guide systems. The tool provides the robot system with changes in the shape of the seam. These values can be used to adapt the process parameters to the current shape. RAPID instructions and functions included in this option CorrCon CorrWrite CorrRead CorrDiscon CorrClear SpcCon SpcWrite SpcDump SpcRead SpcDiscon

30

Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators Activates statistical process supervision Provides the controller with values for statistical process supervision Dumps statistical process supervision data to a file or on a serial channel Reads statistical process supervision information Deactivates statistical process supervision

Product Specification RobotWare Options for BaseWare OS 4.0

SpotWare

3.3 SpotWare SpotWare comprises a large number of dedicated spot welding functions which make the robot well suited for spot welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. Cycle times can be shortened by means of closing the spot welding gun in advance, together with the fact that movement can commence immediately after a spot weld is completed. The robot’s self-optimising motion control, which results in fast acceleration and a quick approach to the spot weld, also contributes to making cycle times shorter. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. SpotWare functions A few examples of some useful functions are given below. Adaptation to different welding guns Gun control (opening and closing) can be programmed freely to suit most types of guns, irrespective of the signal interface. Adaptation to different weld timers The robot can handle different types of weld timers. Normally communication with the weld timer uses parallel signals but a serial interface is also available for some types of weld timers. Continuous supervision of the welding equipment If the option Multitasking is added, supervision can be implemented irrespective of the spotweld instruction. For example, it is possible to monitor peripheral equipment even when program execution has been stopped. Closing the gun It is possible to start closing the spot welding gun before reaching the programmed point. By defining a time of closure, the gun can be closed correctly regardless of the speed of the robot. The cycle time is optimised when the gun is just about to close at the instant when the robot reaches the programmed point. Constant squeeze time Welding can be started directly as the gun closes, i.e. without waiting for the robot to reach its final position. This gives a constant time between gun closure and weld start. Customised Move enable The movement after a completed spot weld can be configured to start either on a user defined input signal or a delay time after weld ready.

Product Specification RobotWare Options for BaseWare OS 4.0

31

SpotWare Immediate move after Move enable The robot moves immediately when enable is given. This is achieved by preparing the next action while waiting for the current weld to be completed. Gun control The system supports double guns, small and large strokes and gun pressure control. Several guns can be controlled in the same program. Testing the program The program can be run one instruction at a time, both forwards and backwards. When it is run backwards, only motion instructions, together with an inverted gun movement, are executed. The program can also be test run without connecting a weld timer or spot welding gun. This makes the program easier to test. Rewelds A function that can be configured to order one or more automatic rewelds or, when the program is restarted after an error, a manual reweld. Process error routines In the event of a process error, installation-specific routines, such as go-to-service position, can be ordered manually. When the appropriate routine has been performed, the weld cycle continues from where it was interrupted. Manual welding independent of positioning A spot weld can be ordered manually at the current robot position. This is implemented in a similar way as for program execution, i.e. with gun control and process supervision. It is also possible to order a separate gun control with full supervision. Interface signals The following process signals are, if installed, handled automatically by SpotWare. Digital outputs start 1 start 2 close tip 1 close tip 2 work select program parity reset fault process error current enable p2 request p3 request p4 request weld power water start manual close gun manual open gun manual run process 32

Description start signal to the weld timer (tip 1) start signal to the weld timer (tip 2) close gun (tip 1) close gun (tip 2) select work or retract stroke of the gun weld program parity bit reset the weld timer operator request is set when an error occurs weld inhibit to the weld timer set pressure 2 set pressure 3 set pressure 4 activate the weld power unit contactor activate water cooling close gun manually open gun manually run a complete spot weld

Product Specification RobotWare Options for BaseWare OS 4.0

SpotWare manual skip process manual new data process run inhibit move weld error

skip the ongoing action send data for the manual actions process is executed block spot welding movement weld ready timeout

Digital output groups program no. initiate

Description weld program number used for several weld timers

Digital inputs weld ready 1 weld ready 2 tip 1 open tip 2 open tip 1 retract tip 2 retract p1 OK p2 OK p3 OK p4 OK timer OK flow OK temp OK current OK

Description weld, started with start 1, is finished weld, started with start 2, is finished the gun (tip 1) is open the gun (tip 2) is open the gun (tip 1) opened to retract stroke the gun (tip 2) opened to retract stroke pressure 1 is reached pressure 2 is reached pressure 3 is reached pressure 4 is reached the weld timer is ready to weld no problem with the water supply no over-temperature the weld current is within permissible tolerances

User defined routines The following routines are predefined but can be adapted to suit the current installation. Routine preweld supervision postweld supervision init supervision motor on action motor off action process OK action process error action current enable action current disable action close gun open gun set pressure service close gun service open gun service weld fault

Description supervision to be done before welding supervision to be done after welding supervision to be done for a warm start action to be taken for Motors On action to be taken for Motors Off action to be taken for welding sensor OK action to be taken for a process error action to be taken for current enable action to be taken for current disable definition of gun closing definition of gun opening definition of gun pressure setting error handling when gun pressure is not achieved error handling at timeout for gun opening error handling at timeout for weld-ready signal

The option Advanced functions is included. RAPID instructions included in this option SpotL

Spot welding with linear movement

Product Specification RobotWare Options for BaseWare OS 4.0

33

SpotWare Plus

3.4 SpotWare Plus In addition to the SpotWare functionality the robot can weld with up to four stationary welding guns simultaneously. RAPID instructions included in this option SpotML

34

Multiple spot welding with linear movement.

Product Specification RobotWare Options for BaseWare OS 4.0

DispenseWare

3.5 DispenseWare The DispenseWare package provides support for different types of dispensing processes such as gluing and sealing. The DispenseWare application provides fast and accurate positioning combined with a flexible process control. Communication with the dispensing equipment is carried out by means of digital and analog outputs. DispenseWare is a package that can be extensively customized. The intention is that the user adapts some user data and routines to suit a specific dispensing equipment and the environmental situation. Dispensing features The DispenseWare package contains the following features: - Fast and accurate positioning. - Handling of on/off guns as well as proportional guns. - Speed proportional or constant analog outputs. - Up to five different guns can be handled simultaneously, controlled by 1 - 5 digital output signals (for gun on/off control) and 1 - 2 analog output signals (for flow control). - Four different gun equipment, each controlled by 1 - 5 digital output signals and 1 - 2 analog output signals, can be handled in the same program. - Possibility to use different anticipated times for the digital and analog signals. - Possibility to use equipment delay compensation for the TCP speed proportional analog signals. - Global or local flow rate correction factors. - Dispensing instructions for both linear and circular paths. - Dispensing in wet or dry mode. - Wide opportunities of customizing the functionality to adapt to different types of dispensing equipment. - Possibility to restart an interrupted dispense sequence. Programming principles Both the robot’s movement and the dispensing process control are embedded in the instructions, DispL and DispC respectively.

Product Specification RobotWare Options for BaseWare OS 4.0

35

DispenseWare The gluing process is specified by: - Bead specific dispensing data. See Data types - beaddata. - Equipment specific dispensing data. See Data types - equipdata. - RAPID routines and global data for customizing purposes. See Predefined Data and Programs - System Module DPUSER. - The I/O configuration. See System Parameters - DispenseWare Dispensing instructions Instruction

Used to:

DispL

Move the TCP along a linear path and perform dispensing with the given data

DispC

Move the TCP along a circular path and perform dispensing with the given data

Dispensing data

36

Data type

Used to define:

beaddata

Dispensing data for the different beads.

equipdata

Dispensing data for the equipment in use.

Product Specification RobotWare Options for BaseWare OS 4.0

PaintWare

3.6 PaintWare PaintWare comprises a large number of dedicated painting functions which make the robot well suited for painting and coating operations. It is powerful, yet simple since both the robot positioning and the paint events are handled in one and the same instruction. All phases of the paint process are controlled, such as start, change, and stop painting, due to trig plane events. The necessary structures for paint process data are predefined and organised as BrushData contained in BrushTables. PaintWare is only available with painting robots. PaintWare functionality When painting, the fluid and air flow through the spray gun is controlled to suit the part being coated and the thickness requirements. These process parameters are changed along the path to achieve optimum control of the paint equipment along the entire path. The paint process is monitored continuously. A set of gun process parameters is called a Brush and it is possible to select different brushes during a linear paint instruction. A brush can contain up to five parameters: Paint Atom_air Fan_air Voltage Rotation

The Paint/Fluid flow reference. The Atomizing air reference. The Shape air reference. The Electrostatic voltage reference. The Rotation speed reference (for rotational applicators).

The five parameters may go directly to analog outputs controlling the spray gun in an open loop system, or may go to dedicated I/O boards for closed loop gun control (IPS). The Brushes are set up as an array, called a BrushTable. A specific BrushTable is selected with the instruction UseBrushTab. The changing of brushes along a path is done using events in the PaintL instruction. The event data describes how a trig plane is located in the active object coordinate system. It also describes which brush to use when the path crosses the plane. Event data may be included in all linear paint instructions as optional arguments. A maximum of ten events can be contained in one PaintL instruction. Data types included in this option BrushData EventData

Data for one brush: flow, atomizing air, fan air, etc. Data for one event: trig-plane (x, y or z), plane value and brush number

Product Specification RobotWare Options for BaseWare OS 4.0

37

PaintWare RAPID instructions included in this option PaintL PaintC UseBrushTab SetBrush GetBrushFactor SetBrushFactor SetTmSignal

38

Paint along a straight path w/paint events Paint along a circular path Used to activate (select) a brush table. Select a brush from the activated brush table. Reads the value of a specified brush factor (function) Writes a new value to a specified brush factor Sets output signals with relative timing

Product Specification RobotWare Options for BaseWare OS 4.0

PalletWare

3.7 PalletWare General The PalletWare package is a set of Rapid modules and user screens, which perform basic operations related to a palletizing or depalletizing process. These operations include a number of services which can be called from a main program to perform pick and place operations for one or up to five palletizing tasks in parallel. For each such task a number of separate dynamic variables are used to describe and keep track of each on-going pallet operation. The PalletWare package is intended to work with Rapid modules generated from PalletWizard, a PC tool for off-line programming of pallet cycles. The PalletWizard is included in the PalletWare package. Pallet cycles Up to five different pallet cycles may be run in parallel, where a pallet cycle is the task to run a complete palletizing job for a pallet, i.e. to pick and place all products, including the pallet itself. Each pallet cycle includes a number of layer cycles, where each layer cycle is the task to complete one layer with all the parts to be picked and placed in this layer. Each layer cycle may further be broken down into a number of pick-place cycles, where each pick-place cycle is the task to pick one or several parts and place them on the pallet. Within each pick-place cycle there may be several place operations, if parts must be placed in many separate operations. Each layer may be either an in-feeder layer, where the products, e.g. boxes, are picked from an in-feeder, or a stack layer, where the product, e.g. an empty pallet, is searched and picked from a stack. If several pallet cycles are run in parallel, then one complete pick-place cycle is always finished before a new one is started in another pallet cycle. Pallet cell The pallet cell may include any number of pallet stations, in-feeders and stacks for pallets, tier sheets or slip sheets. All such stations and stacks are defined as regards position, with an individual coordinate system (work object). The palletizing robot is normally an IRB 6400 or IRB 640 but any robot type may be used. The tool to use may be a mechanical gripper or a tool with suction cups, possibly with separate grip zones for multiple picking and placing. Several different tooldata may be defined and used depending on the product dimensions and number of products.

Product Specification RobotWare Options for BaseWare OS 4.0

39

PalletWare Products Any number of different products with different dimensions may be handled and placed in different patterns on the pallet. Each layer must have the same product only, but different layers on a pallet may have different products. Products may be delivered on one or several in-feeders and placed on one or several different pallets. For each separate product individual handling speeds and load data are used. The dimensions and speeds of the products may be changed in run time, thus affecting all pick and place positions. Movements, approach and retreat positions All movements are calculated in run time and relative to the different coordinate systems defined for each station. Between stations, e.g. moving from an in-feeder to a pallet station, the robot may be forced to move up to safety height and to retract before moving towards the new station. While moving to the pick or place position, the robot will first move to an approach position and then to a prepick/place position. These horizontal and vertical distances for the approach positions, relative to the pick or place position, may be individually defined per product or station. In addition, the approach direction may be individually defined per pick or place position. These approach data may be changed in run time. The picking and placing movements and the sequence to search different stacks for empty pallets or tier sheets may be customised if necessary. User routines A number of different user routines may be called at certain phases of the pallet cycle. These routines can be used for communication with external equipment, for error checking, for operator messages etc. Such user routines are grouped in three main groups according to when they are called in the pallet cycle. The groups are: - Cycle routines, connected to the different cycles, i.e. pallet cycle, layer cycle, pick and place cycle. Each such cycle may have its own individual user routine at the beginning, at the middle and at the end of the cycle. - Station access routines, connected to the different stations. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place on a feeder or pallet station, e.g. to order the next products on the feeder. - Pick stack routines, connected to stacks. Such routines are called to search and pick a product on the stack.

40

Product Specification RobotWare Options for BaseWare OS 4.0

PalletWare User screens The user interacts with the program using menu driven screens on the teach pendant. These screens allow the following functions to be accessed: - Station menu gives access to the robot default parameters, the tool information, the pallet stations, stack stations and feeder station information. - Product menu gives access to the information related to the different types of product: regular products, empty pallets. From here the product dimension may be changed. - Cycles menu gives access to the current production status for the different lines. PalletWare system modules PalletWare consists of a number of system modules as listed below. PalletWare Kernel:

PAL_EXE.sys PAL_DYN.sys PAL_SCR.sys PWUSSC.cfg

Generated from PalletWizard:

PAL_CELL.sys PAL_CYC.sys

Templates to be completed by the system integrator concerning work object data, tool data, user routines including communication with external equipment etc.: PAL_USRR.sys PAL_USRT.sys Modules and code not included in PalletWare In addition to the modules listed above, there are some modules which are not included in the PalletWare delivery, but which must be written by the system integrator for specific installations. These are: - The “main” module, including the main routine. In this routine all logic for working with parallel and simultaneous pallet cycles must be coded by the system integrator, including code required for operator messages, error handling and product changes. - A system module holding different operator dialogues, which may be called from the main routine in order to change or check pallet cycles or to handle error situations.

Product Specification RobotWare Options for BaseWare OS 4.0

41

PalletWare Pallet Wizard Pallet Wizard is a complete stand alone tool, which enables you to describe the full palletizing process via desktop computers running under Windows 95 or Windows NT. The pallet process is a set of components which represents the cell, the products, the in/ out feeders, the layers, the pattern description, and the production cycle. PalletWizard describes a palletizing process with all its components and palletizing cycles. The components describe the objects that will be involved in the process: the robot, the tool, the products and the stations. The palletizing cycles describe the way these static components will operate on each other: how products will be settled in the tool, where products will be picked or placed on different stations. Pallet Wizard allows you to create on PC and maintain on computer disc as many pallet processes as needed. It includes the means of generating and loading the pallet process data and modules in a RAPID format in order for PalletWare to manage them. System requirements for option PalletWare - Option ScreenViewer. - Option Advanced Functions.

42

Product Specification RobotWare Options for BaseWare OS 4.0

Index INDEX

4 Index

procedure call 6 Friction Compensation 10

A

I

Advanced functions 5 arc welding 27, 30 ArcWare 27 ArcWare Plus 30

independent movement 10 input or output signals interrupts 7 InterBus-S 18 interrupt routine movement 7 interrupts from analog input or output signals 7

B BaseWare 5 BaseWare Options 3 BaseWare OS 3 C coating 37 Collision Detection 19 communication robot and PC 13 continuous movement 10 Contour tracking 9 Conveyor Tracking 22 coordinated motion 9 cross-connection locigal conditions 7 D data read and write 5, 13 transfer 5 DispenseWare 35 DP-slave 17 DSQC344 18 E error handler movement 7 External Drive System 10 F fieldbuses 17 file read and write 5, 13 fixed position output 6

L Load Identification 19 logical conditions cross connections 7 O output in fixed position 6 P painting 37 PaintWare 37 parallel processing 12 PLC functionality 7 printout 5 ProcessWare 3, 27 Profibus DP 17 program back-up 13 transfer 13 R read data 5 file 5 Reset the work area 9 S serial channel 5 spot welding 31 SpotWare 31 SpotWare Plus 34

Product Specification RobotWare Options for BaseWare OS 4.0

43

Index

T transfer data 5, 13 file 13 program 13 W World Zones 6 write data 5 file 5

44

Product Specification RobotWare Options for BaseWare OS 4.0

Safety CONTENTS Page 1 Safety ................................................................................................................. 3 1.1 General...................................................................................................... 3 1.1.1 Introduction...................................................................................... 3 1.2 Applicable Safety Standards ..................................................................... 3 1.3 Fire-Extinguishing...................................................................................... 3 1.4 Definitions of Safety Functions.................................................................. 4 1.5 Safe Working Procedures ......................................................................... 4 1.5.1 Normal operations ........................................................................... 4 1.6 Programming, Testing and Servicing......................................................... 5 1.7 Safety Functions........................................................................................ 5 1.7.1 The safety control chain of operation .............................................. 5 1.7.2 Emergency stops............................................................................. 6 1.7.3 Mode selection using the operating mode selector ......................... 6 1.7.4 Enabling device ............................................................................... 8 1.7.5 Hold-to-run control........................................................................... 8 1.7.6 General Mode Safeguarded Stop (GS) connection......................... 9 1.7.7 Automatic Mode Safeguarded Stop (AS) connection ...................... 9 1.7.8 Limiting the working space .............................................................. 9 1.7.9 Supplementary functions ................................................................. 9 1.8 Safety Risks Related to End Effectors ...................................................... 10 1.8.1 Gripper............................................................................................. 10 1.8.2 Tools/workpieces ............................................................................. 10 1.8.3 Pneumatic/hydraulic systems .......................................................... 10 1.9 Risks during Operation Disturbances........................................................ 10 1.10 Risks during Installation and Service ...................................................... 10 1.11 The following standards are of interest when the robot is parts of a cell. 12 1.12 Risks Associated with Live Electric Parts................................................ 12 1.13 Emergency Release of Mechanical Arm ................................................. 13 1.14 Limitation of Liability ................................................................................ 13 1.15 Related Information ................................................................................. 13

Product Manual

1

2

Product Manual

Safety 1 Safety 1.1 General This information on safety covers functions that have to do with the operation of the industrial 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 total system. To protect personnel, the complete system has to be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring 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 have been designed and installed correctly. People who work with robots must be familiar with the operation and handling of the industrial robot, described in applicable documents, e.g. Users’s Guide and Product Manual. The diskettes which contain the robot’s control programs must not be changed in any way because this could lead to the deactivation of safety functions, such as reduced speed. 1.1.1 Introduction Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual/Installation, instructions are provided for connecting safety devices between the robot and the peripheral equipment.

1.2 Applicable Safety Standards The robot is designed in accordance with the requirements of ISO10218, Jan. 1992, Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1999 stipulations.

1.3 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).

Product Manual

3

Safety 1.4 Definitions of Safety Functions Emergency stop – IEC 204-1,10.7 A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous functions 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, hazardous functions 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 the necessary connections for the safeguards and interlocks associated with this circuit. It is 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 should not suffice to initiate any operation. Reduced speed – ISO 10218 (EN 775), 3.2.17 A single, selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either 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/or power 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 causes these 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 circuit may be modified, bypassed or changed in any way, at any time. 1.5.1 Normal operations All normal operations in automatic mode must be executed from outside the safeguarded space.

4

Product Manual

Safety

1.6 Programming, Testing and Servicing The robot is extremely heavy and powerful, even at low speed. When entering into the robot’s safeguarded space, the applicable safety regulations of the country concerned must be observed. Operators must be aware of the fact 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 of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without warning. If work must be carried out within the robot’s work envelope, the following points must be observed: - The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. - The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% – full speed – may only be used by trained personnel who are aware of the risks that this entails. Note! do not change “Transm gear ratio” or other kinematic parameters from the teach pendant or a PC. This will affect the safety function Reduced speed 250 mm/s. - During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. Note! the enabling device must never be rendered inoperative in any way. - The programmer must always take the teach pendant with him/her when entering through the safety gate to the robot’s working space so that no-one else can take over control of the robot without his/her knowledge.

1.7 Safety Functions 1.7.1 The safety control chain of operation The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode. Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode. MOTORS ON mode means that drive power is supplied to the motors. If any contact in the safety chain of operation is open, the robot always reverts to MOTORS OFF mode. MOTORS OFF mode means that drive power is removed from the robot’s motors and the brakes are applied.

Product Manual

5

Safety

K2

K1

K1

Drive Unit

M

K2

Interlocking

EN RUN

&

&

Man2

Man1

+

+ LIM1

Auto1

TPU En1

ES1 GS1

AS1

LIM2 External contactors

TPU En2

ES2 GS2

Auto2 AS2

The status of the switches is indicated by LEDs on top of the panel unit in the control cabinet and is also displayed on the teach pendant (I/O window). After a stop, the switch must be reset at the unit which caused the stop before the robot can be ordered to start again. The time limits for the central two channel cyclic supervisions of the safety control chain is between 2 and 4 second.

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 operator’s panel of the robot controller and on the teach pendant. External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual/Installation). They must be connected in accordance with the applicable standards for emergency stop circuits. Before commissioning the robot, all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation. Before switching to MOTORS ON mode again, establish the reason for the stop and rectify the fault.

6

Product Manual

Safety

1.8 Mode selection using the operating mode selector The applicable safety requirements for using robots, laid down in accordance with ISO/DIS 10218, are characterised by different modes, selected by means of control devices and with clear-cut positions. One automatic and two manual modes are available: Manual mode: < 250 mm/s - max. speed is 250mm/s 100% - full speed Automatic mode: The robot can be operated via a remote control device The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the robot’s safeguarded space. The robot must be operated using the teach pendant and, if 100% is selected, using Hold-to-run control. In automatic mode, the operating mode selector is switched to , and all safety arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. No-one may enter the robot’s safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space. 1.8.1 Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows: ◆ Set the operating mode selector to <250 mm/s ◆ Programs can only be started using the teach pendant with the enabling device activated. The automatic mode safeguarded space stop (AS) function is not active in this mode.

Product Manual

7

Safety 1.8.2 Testing at full speed Robot movements at programmed speed can be carried out as follows: ◆ Set the operating mode selector to 100% ◆ Programs can only be started using the teach pendant with the enabling device activated. For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing the button stops program execution.

Note! the 100% mode may only be used by trained personnel. The applicable laws and regulations of the countries where the robot is used must always be observed. 1.8.3 Automatic operation Automatic operation may start when the following conditions are fulfilled: ◆

The operating mode selector is set to

The MOTORS ON mode is selected Either the teach pendant can be used to start the program or a connected remote control device. These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded space.

◆

1.8.4 Enabling device When the operating mode selector is in the MANUAL or MANUAL FULL SPEED position, the robot can be set to the MOTORS ON mode by depressing the enabling device on the teach pendant. Should the robot revert to the MOTORS OFF mode for any reason while the enabling device is depressed, the latter must be released before the robot can be returned to the MOTORS ON mode again. This is a safety function designed to prevent the enabling device 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.

8

Product Manual

Safety 1.8.5 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 active also 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-run button on the teach pendant must be depressed in order to execute a program. When the button is released, the axis (axes) movements stop and the robot remains in the MOTORS ON mode. Here is a detailed description of how to execute a program in Hold-to-run control: ◆ Activate the enabling device on the teach pendant. ◆ Choose execution mode using the function keys on the teach pendant: - Start (continuous running of the program) - FWD (one instruction forwards) - BWD (one instruction backwards) Wait for the Hold-to-run alert box. ◆ Activate the Hold-to-run button on the teach pendant. Now the program will run (with the chosen execution mode) as long as the Hold-torun button is pressed. Releasing the button stops program execution and activating the button will start program execution again. For FWD and BWD execution modes, the next instruction is run by releasing and activating the Hold-to-run button. It is possible to change execution mode when the Hold-to-run button is released and then continue the program execution with the new execution mode, by just activating the Hold-to-run button again, i.e. no alert box is shown. If the program execution was stopped with the Stop button on the teach pendant, the program execution will be continued by releasing and activating the Hold-to-run button. When the enabling device on the teach pendant is released, the sequence described above must be repeated from the beginning. ◆

1.8.6 General Mode Safeguarded Stop (GS) connection The GS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats. The GS is active regardless of the position of the operating mode selector. When this connection is open the robot changes to the MOTORS OFF mode. To reset to MOTORS ON mode, the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. This is not normally done by resetting the device itself.

Product Manual

9

Safety 1.8.7 Automatic Mode Safeguarded Stop (AS) connection The AS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats used externally by the system builder. The AS is especially intended for use in automatic mode, during normal program execution. The AS is by-passed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position. 1.8.8 Limiting the working space Note! not valid for IRB 340(r) For certain applications, movement about the robot’s main axes must be limited in order to create a sufficiently large safety zone. This will reduce the risk of damage to the 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 by means 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. If necessary, movement of the three wrist axes can also be limited by the computer software. Limitation of movement of the axes must be carried out by the user. 1.8.9 Supplementary functions Functions via specific digital inputs: - A stop can be activated via a connection with a digital input. Digital inputs can be used to stop programs if, for example, a fault occurs in the peripheral equipment. Functions via specific digital outputs: - Error – indicates a fault in the robot system. - Cycle_on – indicates that the robot is executing a program. - MotOnState/MotOffState – indicates that the robot is in MOTORS ON / MOTORS OFF mode. - EmStop - indicates that the robot is in emergency stop state. - AutoOn - indicates that the robot is in automatic mode.

10

Product Manual

Safety

1.9 Safety Risks Related to End Effectors 1.9.1 Gripper If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must be prevented. 1.9.2 Tools/workpieces It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. It should be possible to release parts by manual operation (valves). 1.9.3 Pneumatic/hydraulic systems Special safety regulations apply to pneumatic and hydraulic systems. Residual energy may be present in these systems so, after shutdown, particular care must be taken. The pressure in pneumatic and hydraulic systems must be released before starting to repair 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 to prevent tools, etc., from falling due to gravity.

1.10 Risks during Operation Disturbances If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. Remedial action must only ever be carried out by trained personnel who are familiar with the entire installation as well as the special risks associated with its different parts. The industrial robot is a flexible tool which can be used in many different industrial applications. All work must be carried out professionally and in accordance with applicable safety regulations. Care must be taken at all times.

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11

Safety 1.11 Risks during Installation and Service Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot. Note! to prevent injuries and damage during the installation of the robot system, the regulations 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 the safety function are interlocked in accordance with the applicable standards for that function. - The instructions in the Product Manual/Installation must always be followed. - The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space. - The supplier of the complete system must ensure 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 can be stopped quickly. - Safety zones, which have to be crossed before admittance, must be set up in front of the robot’s working space. Light beams or sensitive mats are suitable devices. - Turntables or the like should be used to keep the operator away from the robot’s 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 robot system in question and in any safety matters associated with it. Although troubleshooting may, on occasion, have to be carried out while the power supply 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 connecting units. 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. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the tie rod. - Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled. - When dismantling/assembling mechanical units, watch out for falling objects. - Be aware of stored energy (DC link) and hot parts in the controller. - Units inside the controller, e.g. I/O modules, can be supplied with external power. 12

Product Manual

Safety

1.12 The following standards are of interest when the robot is parts of a cell EN 294

Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.

EN 349

Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.

EN 811

Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.

Pr EN 999

Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.

EN 1088

Safety of machinery - Inter locking device associated with guards principles for design and selection.

1.13 Risks Associated with Live Electric Parts 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 (55 V AC) - The rectifier unit (260 V AC and 370 V DC. NB: Capacitors!) - The drive unit (370 V DC) - The service outlets (115/230 VAC) - The power supply unit for tools, or special power supply units for the machining process - The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. - Additional connections Manipulator A danger of high voltage is associated with the manipulator in: - The power supply for the motors (up to 370 V DC) - The user connections for tools or other parts of the installation (see Installation, max. 230 V AC) Tools, material handling devices, etc. Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product Manual

13

Safety 1.14 Emergency Release of Mechanical Arm If an emergency situation occur where a person is trapped by the mechanical robot arm, the brake release buttons should be pressed whereby the arms can be moved to release the person. To move the arms by manpower is normally possible on the smaller robots (1400 and 2400), but for the bigger ones it might not be possible without a mechanical lifting device, like an overhead crane. If power is not available the brakes are applied, and therefore manpower might not be sufficient for any robot. Before releasing the brakes, be sure that the weight of the arms does not enhance the pressure on the trapped person.

1.15 Limitation of Liability The above information regarding safety must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.

1.16 Related Information

Described in:

14

Installation of safety devices

Product Manual - Installation and Commissioning

Changing robot modes

User’s Guide - Starting up

Limiting the working space

Product Manual - Installation and Commissioning

Product Manual

To the User

Declaration by the manufacturer

“Declaration by the manufacturer”. as defined by machinery directive 89/392/EEC Annex II B This is only a translation of the customs declaration. The original document (in English) with the serial number on it isthat supplied Herewith we declare the industrial robot together with the robot IRB 140

IRB 340

IRB 640

IRB 1400

IRB 6400S

IRB 6400PE

IRB 6400R

IRB 840

IRB 2400

IRB 4400

manufactured by ABB Robotics Products AB 721 68 Västerås, Sweden with serial No.

Label with serial 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.

IN FO

R

M

AT IO N

Safety of machinery, basic terminology Safety of machinery, technical principles/specifications, emergency stop Safety of machinery, emergency stop equipment Safety of machinery, temperatures of surfaces Safety of machiney, ergonomic design principles Robot safety Electrical equipment for industrial machines 1) Safety of machinery, two-hand control device Safety of machinery, fixed / moveable guards Safety of machinery, safety related parts of the control system EMC, Generic emission standard. Part 2: Industrial environment Radiated emission enclosure Conducted emission AC Mains EMC, Generic immunity standard. Part 2: Industrial environment Electrostatic discharge immunity test Radiated, radio-frequency, electromagnetic field immunity yest Radeated electromagnetic field from digital radio telephones, immunity test Electrical fast transient/burst immunity test Conducted disturbences induced by radio-frequency fields, immunity test

FO R

EN 292-1 EN 292-2 EN 418 EN 563 EN 614-1 EN 775 EN 60204 prEN 574 prEN 953 prEN 954-1 EN 50081-2 EN 55011 Class A EN 55011 Class A EN 50082-2 EN 61000-4-2 EN 61000-4-3 ENV 50204 EN 61000-4-4 ENV 50141

1) There is a deviation from the extra demand for only electromechanical components on emergency stop of category 0 in paragraph 9.2.5.4. EN 60204-1 accepts one channel circuit without monitoring, instead the design is made to comply with category 3 according to EN 954-1, where the demands for redundancy is found.

O N LY

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.  ABB Robotics Products AB

Applied harmonised standards in particular:

Prepared

Responsible department

K-G Johnsson, 000110

SEROP/KM

Approved by,date

Take over department

K-G Ramström, 000119

Technical Provisions

Title

Declaration by the manuf.

Page 1

Product Design Responsible No.of pages

Status

Tillverkardeklaration

APPROVED

Document No

ABB Robotics Products

1 Rev. ind.

3HAB 3585-1

11

ABB ROBOTICS PRODUCTS AB Robot type:

Revision:

For RAC:

RAC Ref no:

Tested and approved:

Date

CONFIGURATION LIST Manufact order no:

Serial no: Sales order no:

Name

MANIPULATOR: CONTROL SYSTEM: To the User ROBOT SYSTEM: The Configuration List is an individual specification of the robot system delivered regarding configuration and extent. Date Delivery from factory: On delivery, the complete document is placed in the robot controller. Delivery to customer: Acceptance by customer: Customer information: Customer: Address:

OPTIONS/DOCUMENTATION QTY

OPTION/PARTNO

REVISION

DESCRIPTION

Fault Tracing Guide CONTENTS Page 1 Fault tracing guide ............................................................................................ 3 1.1 Starting Troubleshooting Work .................................................................. 3 1.2 Diagnostics................................................................................................ 4 1.2.1 Intermittant errors ............................................................................ 6 1.2.2 Tools ................................................................................................ 6 1.2.3 Robot system................................................................................... 6 1.3 Computer System...................................................................................... 7 1.3.1 Indication LEDs on the Various Units .............................................. 7 1.4.1 Signal description, RS 232 and RS 422 .......................................... 10 1.5 Panel unit DSQC 509 ................................................................................ 11 1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant ....................................................................... 12 1.6 Distributed I/O ........................................................................................... 14 1.6.1 Digital and Combi I/O units.............................................................. 15 1.6.2 Analog I/O, DSQC 355 .................................................................... 16 1.6.3 Remote I/O DSQC 350, Allen Bradley............................................. 17 1.6.4 Interbus-S, slave DSQC 351 ........................................................... 18 1.6.5 Profibus-DP, DSQC352 ................................................................... 19 1.6.6 Encoder interface unit, DSQC354 ................................................... 20 1.6.7 Status LEDs description .................................................................. 20 1.7 Serial Communication ............................................................................... 23 1.8 Drive System and Motors .......................................................................... 24 1.9 Teach Pendant .......................................................................................... 24 1.10 Measurement System ............................................................................. 24 1.11 Floppy Disk Drive (Option) ...................................................................... 25 1.12 Fuses....................................................................................................... 25 1.13 SM Bus.................................................................................................... 26 1.14 Digital test inputs ..................................................................................... 26 1.15 Power Supply units.................................................................................. 27 1.16 Connector units ....................................................................................... 27

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2

Product Manual IRB 140

Fault tracing guide 1 Fault tracing guide Sometimes errors occur which neither refer to an error message nor can be remedied with the help of an error message. To make a correct error diagnosis of these particular cases, you must be very experienced and have an in-depth knowledge of the control system. This section of the Product Manual is intended to provide support and guidance in any diagnostic work.

1.1 Starting Troubleshooting Work Generally speaking, troubleshooting should be carried out as follows: u Read any error messages shown on the teach pendant display. What these messages mean is described in System and Error Messages. u Check the LEDs on the units. See Indication LEDs on the Various Units on page 7. u Check the cables, etc., with the help of the circuit diagram. Always start off by consulting a qualified operator and/or check any log books available to get some idea of what has happened, to note which error messages are displayed, which LEDs are lit, etc. If possible, look at the control system’s error log. If there are any error messages there, the log can be accessed from the Service menu. On the basis of this error information, you can start your analysis using the various tools, test programs, measuring points, etc., available. Never start off by wildly replacing boards or units, because this can result in new errors being introduced into the system. Note! when handling units and other electronic equipment in the controller, the wrist strap in the controller must be used to avoid ESD damage.

Product Manual

3

Fault tracing guide 1.2 Diagnostics The control system is supplied with diagnostic software to facilitate troubleshooting and to reduce downtime. Any errors detected by the diagnostics are displayed in plain language with an code number on the display of the teach pendant. All system and error messages are logged in a common log which contains the last 50 messages saved. This enables an “error audit trail” to be made which can be analysed. The log can be accessed from the Service window using the teach pendant during normal operation and can be used to read or delete the logs. All system and error messages available are listed in User’s Guide. 1.2.1 Start up sequence description FAULT LED during start-up

SOLID RED

FLASHING RED t0

t1

FLASHING GREEN t2

SOLID GREEN t3

System Start up

4

Event

Duration

SYSTEM

FAULT LED

TPU

OTHER

t0

---

POWER ON

---

---

---

t0-t1

10 - 15s

RUNNING BIOS

Flashing RED

Indicates communication down

I/O computer starts up on flash image and waits for Main computer to down load the complete image

t1

---

BIOS ready, will now read HD for Operating System

Will continue to flash if no OS is found or if the Hard Drive is not found.

Indicates communication down

t1-t2

10 - 15s

Loading of Operating System, Operating system checks HW configuration

Solid RED

Indicates communication down

Product Manual

Fault tracing guide Event

Duration

SYSTEM

FAULT LED

TPU

t2

---

OS is up, starts to run Robot application (Supplier Application Files)

Will continue Solid RED if the Robot application does not start

Indicates communication down

t2-t3

30 - 60s

The initialising software starts to set up the Robot application (Supplier Application Files)

Flashing GREEN

Starts to communicate, but the window may be empty for up to 30 s more

t3

---

The initialising software is ready.

Will continue to flash if a fatal SW or HW error stops the initialising process

TPU is up unless a fatal error occurred,

t3-

---

System is up

Solid GREEN

TPU is up

OTHER

IO computer down loads about 15s after t2. First CAN indications about 20s after t2. Robot Specific Data Files are loaded.

Entire system ready for use

1.2.2 Intermittent errors Unfortunately, intermittent errors sometimes occur and these can be difficult to remedy. This problem can occur anywhere in the robot and may be due to external interference, internal interference, loose connections, dry joints, heating problems, etc. To identify the unit in which there is a fault, note and/or ask a qualified operator to note the status of all the LEDs, the messages on the teach pendant, the robot’s behaviour, etc., each time that type of error occurs. It may be necessary to run quite a number of test programs in order to pinpoint the error. These are run in loops, which should make the error occur more frequently. If an intermittent error occurs periodically, check whether something in the environment in which the robot is working also changes periodically. For example, it may be caused by electrical interference from a large electric plant which only operates periodically. Intermittent errors can also be caused by considerable temperature changes in the workshop, which occur for different reasons.

Product Manual

5

Fault tracing guide Disturbances in the robot environment can affect cabling, if the cable screen connections are not intact or have been incorrectly connected. 1.2.3 Tools Usually, the following tools are required when troubleshooting: - Normal shop tools - Multimeter - Oscilloscope - Recorder 1.2.4 Robot system In this instance the robot system means the entire robot (controller + manipulator) and process equipment. Errors can occur in the form of several different errors where it is difficult to localise one particular error, i.e. where it is not possible to directly pinpoint the unit that caused the problem. For example, if the system cannot be cold-started, this may be due to several different errors (flash disk failure, computer fault, etc.).

6

Product Manual

Fault tracing guide 1.3 Computer System 1.3.1 Indication LEDs on the Various Units

Transformer

Supply unit

Computer system

Drive unit 1

Drive unit 2

Drive unit 3

DC link

1.4 Location of units in the cabinet

IRB

1400

2400

4400

6400

640

Drive unit

Axes

Axes

Axes

Axes

Axes

Axes

Axes

1

1, 2, 4

1, 2, 4

1, 6

1, 6

1, 6

1(X), 6(C)

2, 1

2

3, 5, 6

3, 5, 6

2, 4

2, 4

2, 3

2(Y), 3(Z)

(4), 3

3, 5

3, 5

3

840/A

340

The computer system consists of the PCI backplane DSQC 501, the main computer DSQC 500, the I/O computer DSQC 522, and the axis computer DSQC 503. Inside the computer chassis there are also the computer power supply DSQC 505, the battery unit DSQC 508, and the flash disk DSQC 518. During start-up of the system a power on self test (POST) is made by the main computer BIOS. If an error is detected by the POST, the start-up procedure will be halted and FAULT LED on the front panel will flash with a red light. If the system fails to start-up, check the LEDs on the main computer’s front panel: Main computer DSQC 500

Product Manual

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Fault tracing guide

X1 Signal name

Pin

Description

TX+

1

Transmit data line +

TX-

2

Transmit data line -

RX+

3

Receive data line +

NC

4

Not connected

NC

5

Not connected

RX-

6

Receive data line -

NC

7

Not connected

NC

8

Not connected

LED

Function

Colour Code

PWR

Power on LED

Green colour: OK Off: Power failure, check computer power supply and power supply cables.

HDD

IOE bus activity LED

Yellow colour: Accessing flash disk Always off: Check flash disk and its cabling/connectors.

FAULT

POST LED

Flashing RED (10s): POST is warning (OK). Flashing RED (forever): POST failure, check main computer board internal cabling and PCI cards. Fixed RED (<1s): Accessing flash disk Master Boot check Fixed RED (forever): Failed to access MBR, check flash disk and its cabling/connectors. Flashing GREEN (<60s): Loading OS and application SW (OK). Flashing GREEN (forever): Failed to start-up system. check flash disk (possible data corruption). Fixed GREEN (forever): System is up and running! (OK).

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Product Manual

Fault tracing guide

It is also possible to connect a terminal on the COM1 serial port to check error log message. COM2 RS232 On computer chassis. Technical data See Product Specification for controller S4Cplus.

Signal

Pin

Description

DCD

1

Data Carrier Detect

DSR

6

Data Set Ready

RX

2

Receive Data

RTS

7

Request to Send

TX

3

Transmit Data

CTS

8

Clear to Send

DTR

4

Data Terminal Ready

RI

9

Ring indicator

GND

5

Signal ground

NC

10

Not Connected

COM1 RS232 Cabinet front (behind service hatch) For temporary use, e.g. connection of Laptop/PC. Technical data See Product Specification for controller S4Cplus.

Product Manual

Signal

Pin

Description

RX

2

Receive Data

TX

3

Transmit Data

GND

5

Signal ground

9

Fault tracing guide 1.4.1 Signal description, RS 232 and RS 422 RS 232 Signal

Explanation

TXD

Transmit Data

RXD

Receive Data

DSR

Data Set Ready

DTR

Data Terminal Ready

CTS

Clear To Send

RTS

Request To Send

Stop bit (“1”) Start bit (“0”) 10 V

0V Byte 1

Byte 2

f=9600/19200 baud

Figure 1 Signal description for RS 232.

The transmission pattern can be single or bursts of 10 bit words, with one start bit “0”, eight data bits (MSB first), and lastly one stop bit “1”. RS 422 Signal

Explanation

TXD4/TXD4 N

Transmit Data in Full Duplex Mode

RXD4/RXD4 N

Receive Data in Full Duplex Mode

DATA4/DATA4 N

Data Signals in Half Duplex Mode

DCLK4/DCLK4 N

Data Transmission Clock

Note! Only full duplex is supported.

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Product Manual

Fault tracing guide

Signal XXX 5V

5V

Signal XXX N

f= 9600 38400 baud Figure 2 Signal description for RS 422, differential transmission.

When measuring the differential RS 422 signals, the oscilloscope should be set for AC testing. The data transmission has the same structure as RS 232, i.e. 1 start bit + 8 data bits + 1 stop bit, but the signals are differential. By looking at the “true” channel, it is possible to read the data. If the types of signal as shown in the above diagram are obtained when measuring, this means that the drive circuits and lines are OK. If one or both of the signals do not move, it is likely that one or several line(s) or one or several drive circuit(s) is/are faulty. 1.4.2 Checking Flash disk capacity Background Flash disks use semiconductors to store data. Each sector has a limited amount of write cycles and will finally be worn out. Flash disk capacity will decrease as sectors are worn put. The rate of the decrease depends on both the application and how much of the capacity is used. Action Check the flash disk capacity. It must not be less than 50 percent of full capacity. If the capacity is less than 50 percent, replace with a new flash disk. There are two sizes of flash disk, 64 Mb and 128 Mb Recommendation - Do not write frequently to the flash disk if it is nearly fully used. - Sectors can be worn out and you may loose data. - Make sure to upgrade in time / Buy enough memory in time.

Product Manual

11

Fault tracing guide 1.5 Panel unit DSQC 509 The main function of the DSQC 509 Panel unit is to monitor the dual run chain. Its status is also indicated by LEDs at the upper part of the unit. Over-temperature of the motors is monitored by PTC inputs to the board. Over-temperature of the transformer is also monitored, as well as drive unit fans and computer system fans.

WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT

EN

MS NS

ES1 ES2 GS1 GS2 AS1 AS2

Status LED’s

LED indications for DSQC 509 Marking

Colour

Meaning

EN

Green

Indicates “go ahead” from the control system

MS

Green/red

Module status, normally green, see also section 1.6

NS

Green/red

Network status, normally green, see also section 1.6

ES 1 and 2

Yellow

EMERGENCY STOP, chain 1 and 2 closed

GS 1 and 2

Yellow

GENERAL STOP switch, chain 1 and 2 closed

AS 1 and 2

Yellow

AUTO STOP switch, chain 1 and 2 closed

The LEDs are very useful when trying to locate errors in the operation chain. Unlit LEDs indicate the whereabouts of an error in the operation chain, making the error easy to locate in the system circuit diagram. 1.5.1 Status of the Panel unit, inputs, and outputs, displayed on the teach pendant - Select the I/O window. - Call up the Units list by choosing View. - Select the Safety unit. The location of the status signals are found in the circuit diagram, regarding Panel unit, where outputs are marked with and inputs with See the table below.

12

Product Manual

Fault tracing guide Outputs DO Name

Significance when “1” is displayed

BRAKE

Energise brake contactor (i.e. release brakes) and turn on duty time counter

MONLMP

Turn on LED in motor-on push button

RUN CH1

Energise motor contactor chain 1

RUN CH2

Energise motor contactor chain 2

SOFT ASO

Choose delayed turn off of auto stop

SOFT ESO

Choose delayed turn off of emergency stop

SOFT GSO

Choose delayed turn off of general stop

Inputs DI Name

Significance when “1” is displayed

AS1

Auto stop chain 1 closed

AS2

Auto stop chain 2 closed

AUTO1

Mode selector chain 1; Auto operation

AUTO2

Mode selector chain 2; Auto operation

CH1

All switches in chain 1 closed

CH2

All switches in chain 2 closed

EN1

Enabling device chain 1 closed

EN2

Enabling device chain 2 closed

ES1

Emergency stop chain 1 closed

ES2

Emergency stop chain 2 closed

ENABLE 1

Enable from I/O computer

ENABLE 2

Enable from axis computer

EXTCONT

External contactors closed

FAN OK

Fan in power supply running

GS1

General stop chain 1 closed

GS2

General stop chain 2 closed

K1

Motor contactor, chain 1, closed

K2

Motor contactor, chain 2, closed

Product Manual

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Fault tracing guide LIM1

Limit switch chain 1 closed

LIM2

Limit switch chain 2 closed

MAN2

Mode selector chain 2; Manual operation

MANFS2

Mode selector chain 2; Manual full speed operation

MANORFS1

Mode selector chain 1; Manual or manual full speed operation

MON PB

Motor-On push button pressed

PTC

Over temperature in motors of manipulator

PTC Ext.

Over temperature in external device

SOFT ASI

Delayed turn off of auto stop (read back of digital output)

SOFT ESI

Delayed turn off of emergency stop (read back of digital output)

SOFT GSI

Delayed turn off of general stop (read back of digital output)

TRFOTMP

Over temperature in main transformer

24V panel

24V panel is higher than 22V

Fan 1-4

Drive unit 1-4 rotation > 1000 rpm

Fan 5-6

Computer system fan 1-2 rotation > 1000 rpm

1.6 Distributed I/O I/O units communicate with the I/O computer, located in the computer system, via the CAN bus. To activate the I/O units they must be defined in the system parameters. The I/O channels can be read and activated from the I/O menu on the teach pendant. In the event of an error in the I/O communication to and from the robot, check as follows: u Is I/O communication programmed in the current program? u On the unit in question, the MS (Module status) and NS (Network status) LEDs must be lit with a fixed green colour. See the table below regarding other conditions. The panel unit is a unit on the CAN-bus, and the behaviour of the MC and NS described is true also for this unit.

14

Product Manual

Fault tracing guide : MS LED is:

To indicate

Action

Off

No power

Check 24 V CAN

Green

Normal condition

Flashing green

Software configuration missing, standby state

Configure device

Flashing red/green

Device self testing

Wait for test to be completed

Flashing red

Minor fault (recoverable)

Restart device

Red

Unrecoverable fault

Replace device

1.6.1 Digital and Combi I/O units All the I/O units have the same LED indications. The figure below shows a digital I/O unit, DSQC 328. The description below is applicable for the following I/O units: Digital I/O DSQC 328, Combi I/O DSQC 327, Relay I/O DSQC 332 and 120 VAC I/O DSQC 320.

Status LED’s

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

X1

X3

OUT 9

10

11

12

13

14

15

16

IN

X2 1

1

12

1

10

10

X4 1

10

10

1 X5

Product Manual

15

Fault tracing guide

Designation

Colour

Description/Remedy

IN

Yellow

Lights at high signal on an input. The higher the applied voltage, the brighter the LED will shine. This means that even if the input voltage is just under the voltage level “1”, the LED will glow dimly.

OUT

Yellow

Lights at high signal on an output. The higher the applied voltage, the brighter the LED will shine.

MS/NS

Green/red

See section 1.6.7.

1.6.2 Analog I/O, DSQC 355

Bus status LED’s Bus status LED’s

X8

X7

S2 S3 X2 X5 X3

MS

Analog I/O

DSQC 355

N.U RS232 Rx CAN Rx +5V +12V

N.U RS232 Tx CAN Tx -12V NS

ABB flexible Automation

Designation

Colour

Description/Remedy

NS/MS

Green/red

See section 1.6.7.

RS232 Rx

Green

Indicates the state of the RS232 Rx line. LED is active when receiving data. If no light, check communication line and connections.

RS232 Tx

Green

Indicates the state of the RS232 Tx line. LED is active when transceiving data. If no light when transmission is expected, check error messages and check also system boards in rack.

Green

Indicates that supply voltage is present and at correct level. Check that voltage is present on power unit. Check that power is present in power connector. If not, check cables and connectors. If power is applied to unit but unit does not work, replace the unit.

+5VDC / +12VDC / -12VDC

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Product Manual

Fault tracing guide 1.6.3 Remote I/O DSQC 350, Allen Bradley

POWER NS MS CAN Tx CAN Rx NAC STATUS

Bus status LED’s POWER NS MS CAN Tx CAN Rx

X5 X9

X3

X8 DSQC 350

NAC STATUS

ABB Flexible Automation

Designation

Colour

Description/Remedy

POWER-24 VDC

Green

Indicates that a supply voltage is present, and has a level above 12 VDC.If no light, check that voltage is present on power unit. That power is present in power connector. If not, check cables and connectors.If power is applied to unit but unit does not work, replace unit.

NS/MS

Green/red

See section 1.6.7.

CAN Tx/CAN Rx

Yellow

See section 1.6.7.

NAC STATUS

Green

Steady green indicates RIO link inoperation.If no light, check network, cables and connections.Check that PLC is operational.Flashing green, communication established, but INIT_COMPLETE bit not set in NA chip, or configuration or rack size etc. not matching configuration set in PLC.If LED keeps flashing continuously, check setup

Product Manual

17

Fault tracing guide 1.6.4 Interbus-S, slave DSQC 351 Bus status LED’s X21

Interbus-S

X5

18

POWER RBDA BA RC

DSQC 351

RC BA RBDA POWER

CAN Rx CAN Tx MS NS POWER

POWER NS MS CAN Tx CAN Rx

ABB Flexible Automation

X20

X3

Designation

Colour

Description/Remedy

POWER-24 VDC

Green

Indicates that a supply voltage is present, and has a level above 12 VDC.

NS/MS

Green/red

See section 1.6.7.

CAN Tx/CAN Rx

Green/red

See section 1.6.7.

POWER- 5 VDC

Green

Lit when both 5 VDC supplies are within limits, and no reset is active.

RBDA

Red

Lit when this Interbus-S station is last in the Interbus-S network. If not as required, check parameter setup.

BA

Green

Lit when Interbus-S is active. If no light, check network, nodes and connections.

RC

Green

Lit when Interbus-S communication runs without errors.

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Fault tracing guide

PROFIBUS ACTIVE

Profibus

NS MS CAN Tx CAN Rx POWER

X5

Bus status LED’s Profibus active NS MS CAN Tx CAN Rx

DSQC 352

X20

ABB Flexible Automation

1.6.5 Profibus-DP, DSQC352

Power

X3

Designation

Colour

Description/Remedy

Profibus active

Green

Lit when the node is communicating with the master. If no light, check system messages in robot and in Profibus net.

NS/MS

Green/red

See section 1.6.7.

CAN Tx/CAN Rx

Green/red

See section 1.6.7.

POWER, 24 VDC

Green

Indicates that a supply voltage is present, and has a level above 12 VDC.If no light, check that voltage is present in power unit.Check that power is present in the power connector. If not, check cables and connectors. If power is available at the unit but the unit does not function, replace the unit

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Fault tracing guide 1.6.6 Encoder interface unit, DSQC354

ABB Flexible Automation

Status LED’s X20

Encoder

CAN Rx CAN Tx MS NS POWER

X5

ENC 1A ENC 1B DIGIN 1

DSQC 354

Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A

POWER NS MS CAN Tx CAN Rx

X3

Designation

Colour

Description/Remedy

POWER, 24 VDC

Green

Indicates that a supply voltage is present, and has a level above 12 VDC.If no light, check that voltage is present on power unit. That power is present in connector X20. If not, check cables and connectors.If power is applied to unit but unit does not work, replace unit.

NS/MS

Green/ red

See section 1.6.7.

CAN Tx/CAN Rx

Yellow

See section 1.6.7.

ENC 1A/1B

Green

Indicates phase 1 and 2 from encoder.Flashes by each Encoder pulse.By frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker).If no light, faulty power supply for input circuit (internal or external). Defective input circuit on board. External wiring or connectors, short circuit or broken wire.Internal error in unit. Constant light indicates constant high level on input and vice versa. No light in one LED indicates fault in one encoder phase.

DIGIN1

Green

Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point.If no light, faulty limit switch, photocell etc. External wiring or connectors, short circuit or broken wire. Faulty power supply for input circuit (internal or external). Defective input circuit on board.

1.6.7 Status LEDs description Each of the units connected to the CAN bus includes 2 or 4 LED indicators which 20

Product Manual

Fault tracing guide indicate the condition (health) of the unit and the function of the network communication. These LEDs are: All units MS - Module status NS - Network status Some units: CAN Tx - CAN network transmit CAN Rx - CAN network receive MS - Module status This bicolour (green/red) LED provides device status. It indicates whether or not the device has power and is operating properly. The LED is controlled by software. The table below shows the different states of the MS LED.

Description

Remedy / Source of fault

Off

No power applied to the device.

Check power supply.

Green

Device is operating in a normal condition.

If no light, check other LED modes.

Flashing green

Device needs commissioning due to configuration missing, incomplete or incorrect. The device may be in the Stand-by state.

Check system parameters. Check messages.

Flashing red

Recoverable minor fault.

Check messages.

Red

The device has an unrecoverable fault.

Device may need replacing.

Flashing red/green

The device is running self test.

If flashing for more than a few seconds, check hardware.

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Fault tracing guide NS - Network status The bicolour (green/red) LED indicates the status of the communication link. The LED is controlled by software. The table below shows the different states of the NS LED.

Description

Remedy / Source of fault

Off

Device has no power or is not on-line. The device has not completed the Dup_MAC_ID test yet.

Check status of MS LED. Check power to affected module.

Flashing green

Device is on-line, but has no connections in the established state. The device has passed the Dup_MAC_ID test, is on-line, but has no established connections to other nodes. For a group 2 only device it means that the device is not allocated to a master. For a UCMM capable device it means that the device has no established connections.

Check that other nodes in network are operative. Check parameter to see if module has correct ID.

Green

The device is on-line and has connection in the established state. For a group 2 only device it means that the device is allocated to a master. For a UCMM capable device it means that the device has one or more established connections.

If no light, check other LED modes.

Flashing red

One or more I/O connections are in the Time-Out state.

Check system messages.

Red

Failed communication device. The device has detected an error that has rendered it incapable of communicating on the network. (Duplicate MAC_ID, or Bus-off).

Check system messages and parameters.

Module- and network status LEDs at power-up The system performs a test of the MS and NS LEDs during start-up. The purpose of this test is to check that all LEDs are functioning properly. The test runs as follows: - NS LED is switched Off. - MS LED is switched On green for approx. 0.25 seconds. - MS LED is switched On red for approx. 0.25 seconds. - MS LED is switched On green. - NS LED is switched On green for approx. 0.25 seconds. - NS LED is switched On red for approx. 0.25 seconds. - NS LED is switched On red. If a device has other LEDs, each LED is tested in sequence.

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Product Manual

Fault tracing guide CAN Tx - CAN network transmit

Description

Remedy / Source of fault

Green LED. Physically connected to the Can Tx line. Flashes when the CPU is receiving data on the CAN bus.

If no light when transmission is expected, check error messages. Check system boards in rack.

CAN Rx - CAN network receive

Description

Remedy / Source of fault

Green LED. Physically connected to the Can Rx line. Flashes when the CPU is transmitting data on the Can bus.

If no light, check network and connections.

NS LED is:

To indicate

Off

Not powered/not on-line

Flashing green

On-line, not connected

Green

On-line, connections established

Red

Critical link failure, incapable of communicating (duplicate MAC ID, or bus-off)

Action

Wait for connection

Change MAC ID and/or check CAN connection/ cables

Check that the current I/O signal has the desired status using the I/O menu on the teach pendant display. u Check the I/O unit’s LED for the current input or output. If the output LED is not lit, check that the 24 V I/O power supply is OK. u Check on all connectors and cabling from the I/O unit to the process connection. u

1.7 Serial Communication The most common causes of errors in serial communication are faulty cables (e.g. send and receive signals are mixed up) and transfer rates (baud rates), or data widths that are incorrectly set. If there is a problem, check the cables and the connected equipment before doing anything else. The communication can be tested using the integral test program, after strapping the input to the output. See chapter 9.

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Fault tracing guide 1.8 Drive System and Motors The drive system, which consists of rectifier, drive unit, and motor, is controlled by the axis computer. .

Computer

Rotor position

DC link

Serial measurement board

Torque reference

Drive Unit

M

R

Figure 3 A schematic description of the drive system.

The drive system is equipped with internal error supervision. An error is sent on via the axis computer and can be read on the teach pendant display as an error message. An explanation of the available error messages can be found in the User’s Guide, System and error messages, section 3, error no. 39XXX. If a drive unit or rectifier is faulty, the unit should be replaced. Internal troubleshooting cannot be performed in the operating environment.

1.9 Teach Pendant The teach pendant communicates with the I/O computer via a cable. This cable is also used for the +24 V supply and the dual operation chain. If the display is not illuminated, try first adjusting the contrast, and if this does not help, check the 24 V power supply. Communication errors between the teach pendant and the I/O computer are indicated by an error message on the teach pendant. For measuring points for the teach pendant communication signals, see chapter 9.

1.10 Measurement System The measurement system comprises an axis computer, one or more serial measurement boards and resolvers. The serial measurement board is used to collect resolver data. The board is supplied from 24 V SYS via a fuse on the connector unit. The board is located in the manipulator and has a battery backup. Communication with the axis computer takes place across a differential serial link (RS 422). The measurement system contains information on the position of the axes and this information is continuously updated during operation. If the resolver connections are disconnected or if the battery goes dead after the robot has been stationary for a long period of time, the manipulator’s axis positions will not be stored and must be updated. The axis positions are updated by manually jogging the manipulator to the synchronised position and then, using the teach pendant, setting the counters to zero. If you try to start program execution without doing the above, the system will give an 24

Product Manual

Fault tracing guide alarm to indicate that the system is not calibrated. Note that it is necessary to re-calibrate after the resolver lines have been disconnected. This applies even if the manipulator axes have not been moved. Transmission errors are detected by the system’s error control, which alerts and stops program execution if necessary. Common causes of errors in the measurement system are line breakdown, resolver errors, and measurement board interference. The latter type of error relates to the 7th axis, which has its own measurement board. If it is positioned too close to a source of interference, there is a risk of an error.

1.11 Floppy Disk Drive (Option) The disk drive is controlled by the Main computer via a ribbon cable. The power is supplied in the same cable (shielded ribbon cable). Common types of error are read and write errors, generally caused by faulty diskettes. In the event of a read and/or write error, format a new, high quality diskette in the robot and check to see whether the error disappears. If the error is still present, the disk drive will probably have to be replaced. However, check the ribbon cable first. NB: Never use diskettes without a manufacturer’s mark. Unmarked, cheap diskettes can be of very poor quality. If the disk drive is completely dead, check the supply voltage connection to the disk drive to see that it is +5 V, before replacing the drive. It is accessible on a two pin connector on the computer chassis. When replacing the disk drive, check that the strapping is set correctly on the unit. Compare with the faulty drive being replaced.

1.12 Fuses There is one automatic three-phase 20 A fuse that supplies the DC-link in the MOTORS ON state, on the transformer. There is also a automatic three-phase 10 A fuse that supplies the power supply unit. There are also two fuses for customer AC supplies, one 3.15 A and one 6.3 A. The base connector unit has six PTC resistance fuses: - Serial measurement system channel 1 - Serial measurement system channel 2 - CAN 1.1 - CAN 1.2 - CAN 1.3 - CAN 2 The fuses protect against 24 V short-circuits and return to the normal state when there is no longer a risk of short-circuiting. The panel unit has one PTC fuse to protect the motor on chains. An open fuse is indicated on the teach pendant, see 1.5.1, 24 panel. The cabling from the customer 24 V supply is protected by a 2A fuse on terminal Product Manual

25

Fault tracing guide XT31 in the upper compartment of the controller. The floppy disk drive power supply is protected with a resetable fuse inside the computer power supply DSQC 505. Note that the process power supply unit DSQC 506 is provided with a short circuit energy limitation, individual for each supply voltage, which makes the fuse unnecessary.

1.13 SM Bus The SM Bus is a serial bus protocol that is developed for the I2C hardware bus. The protocol is very simple and intended for low bandwidth applications. A typical implementation is PC supervision of a power supply. In the ABB Controller, the bus is used by a number of peripherals to communicate their current status. Three units are currently connected to this bus. Each of them has at least one unique address that may appear in the System logs.

Type

26

Unit

Address 1

Address 2

Information

DSQC 505

Computer Power Supply

39

N/A

1. Reports status of incoming voltage 2. Supervises its own outputs: 3,3V 5V +/- 12V

DSQC 506

Process Power Supply

38

N/A

1. Reports status of internal fan. 2. Supervises its own outputs: 24V +/- 15V

DSQC 508

Battery Backup Unit

33

35

NOTE: This unit has 2 addresses, representing 2 registers. 1. Reports current energy level. 2. Reports own health.

Product Manual

Fault tracing guide

1.14 Power Supply units DSQC 506

X6

X2

X3 X5 X4

X1

Designation

Colour

Description/Remedy

AC OK

RED/GREEN

3 x 55V supply OK (start of ENABLE chain)

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Fault tracing guide 1.15 Connector units LED indicators CAN 1 NS MS and CAN 2 NS MS show CAN module status for the I/O computer DSQC 522.

LED indications for DSQC 504 Marking

Colour

Significance

MS

Green/red

Module status, normally green, see also section 1.6

NS

Green/red

Network status, normally green, see also section 1.6

The LEDs are very useful when trying to locate errors in the operation chain. Unlit LEDs indicate the whereabouts of an error in the operation chain, making the error easy to locate in the system circuit diagram.

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Decommissioning CONTENTS Page 1 Decommissioning ............................................................................................. 1.1 General...................................................................................................... 1.1.1 Manipulators .................................................................................... 1.1.2 Controller ......................................................................................... 1.2 Scrapping .................................................................................................. 1.2.1 General warning .............................................................................. 1.2.2 Oil and grease ................................................................................. 1.2.3 Parts requiring special treatment when scrapping........................... 1.3 IRB 4400 ................................................................................................... 1.4 IRB 6400 and IRB 640 .............................................................................. 1.4.1 Scraping Balancing cylinders ..........................................................

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3 3 3 4 4 4 4 4 5 5 6

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Decommissioning CONTENTS Page

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Decommissioning 1 Decommissioning 1.1 General The components of the robot are manufactured from many different materials. Some of them are listed below to facilitate scrapping, i.e. so that the components can be disposed of in a way that does not have a detrimental effect on anyone’s health or the environment. 1.1.1 Manipulators

Material

Examples of components

Part of

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

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Decommissioning

1.1.2 Controller

Material

Examples of components

Copper

Transformers, cables

Tin

Cables

Alu-Zinc sheeting

Control cabinets, various sheet metal parts

Iron

Transformers

Polyester

Circuit boards

Plastic/rubber (PVC)

Cables, connectors, teach pendant, covers (drive units, I/O units) etc.

Lithium

Batteries

1.2 Scrapping The Counter-weight for 6400 and 640 contains lead and must therefore always be recycled. 1.2.1 General warning Before removing any parts from the manipulator, study the dismantling instructions for the component in question. Dismantling instructions can be found in under Repairs. 1.2.2 Oil and grease Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorised person/contractor in accordance with local regulations. Do not dispose of oil 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. 1.2.3 Parts requiring special treatment when scrapping Special care is needed when removing certain parts from the robot, before scrapping the part in question. The types of robot on which there are such parts are listed below together with a description of how they should be removed.

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Decommissioning

1.3 IRB 4400 Balancing cylinder The balancing cylinder contains 3 preloaded spiral springs (see Figure 1). Before scrapping (melting down, or other form of destruction) the springs must be unloaded in a safe way. Spiral spring

Free length of spiral spring: L = 470 mm Figure 1Balancing cylinder IRB 4400.

1.4 IRB 6400 and IRB 640 Balancing cylinder The balancing cylinder contains 1-2 preloaded spiral springs. (see Figure 2) Before scrapping (melting down, or other form of destruction) the springs must be unloaded in a safe way, (see chapter Scraping Balancing cylinders on page 6). There are different types of balancing cylinder with a preloading force between 45008000 N. Free length of unloaded springs = is about 300 - 400 mm. besides the length of the balancing cylinder.

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Decommissioning

Double Spiral spring

Singel Spiral spring

Figure 2Balancing cylinder, IRB 6400 and 640.

1.4.1 Scraping Balancing cylinders Normal way to Scrap the balancing cylinders is using a so-called shredder or scrapping mill, all the balancing cylinders can be treated this in way. An all covered mill where the scrap is ground to ships by e.g (“Newell heavy duty shredder plant 2205”) or similar, scrapping mills are available at all bigger scrapmerchants. Alternative ways If scrapping mills are not available the balancing cylinders except 3HAA 0001-EZ can be opened by means of a blowpipe acc. to the sketches (see Scraping Balancing cylinders on page 7). It is most important that no closed rooms remains when the scrap is shipped to the steel plant for recycling. Part no. 3HAA 0001-US. Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered spring so it will be possible to cut another hole (200 x 100 mm) in the inner mantel surface, cut the inner spring., cut off the piston rod end see Figure 3. ◆ Part no.3HAB 5970-1, 3HAB 5971-1, 3HAB 4175-2 and 3HAB 4175-3 ◆

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Product Manual

Decommissioning Cut a hole (250 x 150 mm) in the mantel surface, and then cut all the uncovered spring. Finally cut a hole (40 mm) in the piston rod (alt.A) or cut off the piston rod end (alt.B) see Figure 4. ◆ Part no. 3HAA 0001-EZ and 3HAA 0001-EX This type of Balancing cylinder has an outer jacket of aluminium which means it can not be opened by means of a blowpipe, besides, the aluminium must be separated from steel before recycling, and that can only be done in a shredder or by the manufacturer. see Figure 5.

ca. 250

Cut off Piston rod

ca. 200

Figure 3Scraping Balancing cylinders

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Decommissioning

ca. 250 Ca Ø 40mm Cut off Spiral spring

Hole in the Piston rod

Alternative A

ca. 250

Cut off Piston rod

Cut off Spiral spring

Alternative B

Figure 4Scraping Balancing cylinders

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Decommissioning

Figure 5Scraping Balancing cylinders

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Decommissioning

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Description CONTENTS Page 1 Computer System ............................................................................................. 3 2 Servo System .................................................................................................... 5 2.1 Principle function ....................................................................................... 5 2.2 Regulation ................................................................................................. 5 2.3 Controlling the robot .................................................................................. 5 2.4 Overload protection ................................................................................... 6 3 I/O System.......................................................................................................... 7 4 Safety System.................................................................................................... 9 4.1 The chain of operation............................................................................... 9 4.2 MOTORS ON and MOTORS OFF modes................................................. 10 4.3 Safety stop signals .................................................................................... 10 4.4 Limitation of velocity .................................................................................. 10 4.5 ENABLE .................................................................................................... 11 4.6 24 V supervision........................................................................................ 11 4.7 Monitoring.................................................................................................. 11 5 External Axes .................................................................................................... 13

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Description CONTENTS Page

2

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Description

Computer System

1 Computer System The computer system is made up of three computers boards. The computers comprise: Main computer board contains the main computer of the robot and controls the entire robot. Axis computer board Regulates the velocity and torque of up to 7 axes. Set points for position are sent from the main computer to the axis computer. The axis computer receives position set values from the main computer and current position from the serial measurement board. The axis computer use this data in regulating algoritms and transmitts torque set value and position values to the drive system. I/O computer board Is as a link between the main computer and the process equipment (e.g I/O units). To find out where the various boards are located, see Electronics unit on page 4. 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 contain functions for coordinating and regulating the axis movements. Figure 1 shows how the computer system communicates with the other units. Optional boards (0-5) Extra axis computer (s) Needed for contorl of additional external axes. Extra I/O computer Needed for extra I/O chanels (CAN buses, Ethernet). Field bus boards E.g. Profibus DP, Interbus-S, ContolNet.

Product Manual Controller

3

Description

Computer System

Ethernet

Serial ports Com 1, Com 2

Flash disk USB

SMBus Battery unit

Floppy disk drive (Option)

Computer power supply

Main computer See Figure 3

Cooling fans

Process power supply

Test inputs Measurement system 1 Drive system 1 Measurement system 2 Drive system 2 Enable 2

Axis computer 2

See Figure

Serial channels SIO1, SIO2 TPU

PCI bus

Ethernet

I/O computer See Figure 3

Enable 1 Panel unit CAN CAN

Optional board (0-5) See Figure 3

Gateway units I/O units (Optional) I/O units (Optional)

Field bus boards

Figure 1 The interfaces of the computer system.

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Product Manual Controller

Description

Servo System

2 Servo System 2.1 Principle function The servo system is a complex system comprising several different interacting units and 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 received from the serial measurement board. This data is input into the position regulator and then compared with previous position data. After it has been compared and amplified, new references are given for the pose and velocity of the robot. The system also contains a model of the robot which continuously calculates the optimal regulator parameters regarding the gravity, moment of inertia and interaction between axes. See Figure 2System structure for AC operation..

2.3 Controlling the robot A digital current reference for two phases is calculated on the basis of the resolver signal and a known relationship between the resolver angle and rotor angle. The third phase is created from the other two. The current of the phases is regulated in the drive unit in separate current regulators. 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 resolvers and generates information on the position of the resolvers. The following diagrams outline the system structure for AC operation as well as the fundamental structure of the drive unit

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5

Description

Servo System

. Measurement System 1/2 Computer Serial measurement board

Drive System 1/2 DC Link

Drive unit

M

R PWM

DC Link

Torque reference Rotor positon

Current Estimator

M

PWM U

M

W

PWM

M

V M

PWM Power circuits

Figure 2System structure for AC operation.

2.4 Motor Overload PTC resistance is built into the robot motors to provide thermal protection against overloads. The PTC sensors are connected to an input on the panel unit which is sensitive to resistance level and which check that low resistance is maintained. The robot computer checks the motors for overloading at regular intervals by reading the panel unit register. In the event of an overload, all motors are switched off.

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Product Manual Controller

Description

I/O System

3 I/O System Communicates with other equipment using digital and analog input and output signals.

Flash disk ATA / EIDE RS 232 Com2

USB

Floppy disk

Main Computer PCI bus Ethernet

I/O Computer TPU CAN2 RS 422 SIO2 RS 232 SIO1

General Serial ports

CAN1

16 16

I/O unit (s)

Gateway unit I/O

I/O

I/O

Safety Signals

Panel unit Field bus Master/Slave boards Profibus DP Interbus-S ControlNet

Figure 3Overview of the I/O system.

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I/O System

8

Description

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Description

Safety System

4 Safety System The robot’s safety system is based on a two-channel safety circuit that is continuously monitored. If an error is detected, the power supply to the motors is switched off and the brakes engage. To return the robot to MOTORS ON mode, the two identical chains of switches must be closed. As long as these two chains differ, the robot will remain in the MOTORS OFF mode. Figure 4 below illustrates an outline principal circuit with available customer contacts.

Solid State Switch LS Contactor ES 2nd chain interlock

GS

Drive units

&

TPU En

EN 1 / 2 RUN

M Auto

Manual

Operating mode selector

LS = Limit switch AS = Automatic mode safeguars space stop TPU En = Enabeling device GS = General mode safeguard space stop ES = Emergency stop EN1/2 = Enable signals from I/O and axis computer respectively.

Figure 4Outline diagram of one of the safety circuits.

4.1 The chain of operation The emergency stop buttons on the operator’s panel, on the teach pendant and external emergency stop buttons are included in the two-channel chain of operation. A safeguarded stop, AUTO STOP, which is active in the AUTO operating mode, can be connected by the user. In any of the MANUAL modes, the enabling device on the teach pendant overrides the AUTO STOP. The safeguarded stop GENERAL STOP is active in all operating modes and is connected by the user. The aim of these safeguarded stop functions is to make the area around the manipulator 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, the motor contactors drop out, and the robot is stopped by the brakes. If the safety circuit breaks, an interrupt call is sent directly from the panel unit to the computer system to ensure that the cause of the interrupt is indicated. When the robot is stopped by a limit switch, it can be moved from this position by Product Manual Controller

9

Safety System

Description

jogging it with the joystick while pressing the MOTORS ON button. The MOTORS ON 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 quick location of the position where the safety chain is opened. The LEDs are located on the upper part of the panel unit. Status indication is also available on the teach pendant display.

4.2 MOTORS ON and MOTORS OFF modes The principle task of the safety circuit is to ensure that the robot goes into MOTORS OFF mode as soon as any part of the chain is opened. The computer system itself controls the last switch. In AUTO mode, you can switch the robot back on by pressing the MOTORS ON button on the operator’s panel. If the circuit is OK, the computer system then closes the Solid state switch to complete the circuit. When switching to MANUAL, the mode changes to MOTORS OFF, at which stage the computer system also opens the Solid state switch. In any of the MANUAL modes, you can start operating again by pressing the enabling device on the teach pendant. If the circuit is OK, the computer system then closes the Solid state switch to complete the circuit. The function of the safety circuit can be described as a combination of mechanical switches and computer system controlling.

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 two categories of safety stops, category 0 and category 1. A safety analysis will show if category 0 or 1 is applicable, see below: The category 0 stop is to be used when the power supply to the motors must be switched off immediately, such as when a light curtain, used to protect against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop. Category 1 is preferred if it is acceptable, such as when gates are used to protect against entry into the work cell. This controlled motion stop takes place within the programmed path, which makes restarting easier. All the robot’s safety stops are of type 0 stops as default. Safety stops of category 1 can be obtained by activating the soft stop (delayed stop) together with AS or GS. Activation is made by setting a parameter, see User’s Guide, section System Parameters, Topic: Controller.

4.4 Limitation of velocity To program the robot, the operating mode switch must be turned to MANUAL REDUCED SPEED position. Then the robot’s maximum velocity is limited to 250

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Product Manual Controller

Description

Safety System

mm/s.

4.5 ENABLE ENABLE 1 and ENABLE 2 are signals to the panel unit from the I/O computer and axis computer respectively. ENABLE 1 is affected if any error occurs in the execution of the I/O computer program, and ENABLE 2 is affected if any error occurs in the execution of the axis computer program. ENABLE 1 and ENABLE 2 can also be affected by the main computer. The main computer monitor program execution of both the I/O computer and the axis computer. Likewise the I/O computer and the axis computer monitor the program execution of the main computer. If any computer detects an error it affect either one of the ENABLE 1and ENABLE 2.

4.6 24 V supervision If the 24 V supply to the safety circuits drops out, the MOTORS ON contactors will drop out, causing the motors to switch off and a message on the TPU will appear.

4.7 Monitoring Monitoring is carried out using both hardware and software, and comprises the external part of the safety circuits, including switches and operating contacts. The hardware and software parts operate independently of each other. The following errors may be detected: All inputs from the safety circuits are linked to registers, which allows the computer system to monitor the status. If an interrupt occurs in the circuit, the status can be read. If any of the switch functions are incorrectly adjusted, causing only one of the chains of operation to be interrupted, the computer system will detect this. By means of hardware interlocking it is not possible to enter MOTORS ON without correcting the cause.

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Safety System

12

Description

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Description

External Axes

5 External Axes Not valid for IRB 340(r)! External axes are controlled by drive units, mounted either inside the controller or outside in a separate enclosure, see Figure 5. The maximum of drive units mounted inside the controller is one or two, depending on robot type. In addition to drive units from ABB, it is also possible to communicate with external drive units from other vendors. See Product Specification RobotWare for BaseWare OS 4.0. Not supplied on delivery SMB

SMB

Measurement System 2 SMB

SMB

alt.

Not supplied on delivery

Drive System 2 inside user designed cabinet (no ABB drives)

Measurement System 1

SMB

Not supplied on delivery Figure 5Outline diagram, external axes.

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External Axes

14

Description

Product Manual Controller

Installation and Commissioning CONTENTS Page 1 On-Site Installation ........................................................................................... 5 1.1 Transporting and Unpacking ..................................................................... 5 1.2 System CD ROM and diskette .................................................................. 5 1.3 Lifting the Cabinet ..................................................................................... 5 1.4 Amount of space required ......................................................................... 6 1.5 Bolting the cabinet..................................................................................... 8 1.6 Connecting the manipulator to the controller............................................. 8 1.6.1 Connection on left-hand side of cabinet .......................................... 8 1.7 Mains power connection............................................................................ 9 1.7.1 Connection to the mains switch....................................................... 9 1.7.2 Connection via a power socket........................................................ 10 1.8 Inspection before start-up.......................................................................... 10 1.9 Start-up...................................................................................................... 11 1.9.1 General............................................................................................ 11 1.9.2 Updating the revolution counter....................................................... 12 1.9.3 Checking the calibration position..................................................... 14 1.9.4 Alternative calibration positions ....................................................... 15 1.9.5 Operating the robot.......................................................................... 15 2 Connecting Signals........................................................................................... 17 2.1 Signal classes ........................................................................................... 17 2.2 2.3 2.4 2.5

Selecting cables ........................................................................................ 17 Interference elimination ............................................................................. 18 Connection types....................................................................................... 19 Connections .............................................................................................. 19 2.5.1 To screw terminal............................................................................. 19 2.5.2 To connectors (option) ..................................................................... 19 2.6 Connection to screw terminal .................................................................... 21 2.7 The MOTORS ON / MOTORS OFF circuit................................................ 23 2.7.1 Connection of safety chains ............................................................ 24 2.7.2 Connection of ES1/ES2 on panel unit ............................................. 25 2.7.3 Connection to Motor On/Off contactors ........................................... 26 2.7.4 Connection to operating mode selector........................................... 26 2.7.5 Connection to brake contactor......................................................... 26 2.8 External customer connections ................................................................. 27 2.9 External safety relay.................................................................................. 30 2.10 Safeguarded space stop signals ............................................................. 31 Product Manual Controller

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Installation and Commissioning CONTENTS Page 2.10.1 Delayed safeguarded space stop .................................................. 31 2.11 Available voltage ..................................................................................... 31 2.11.1 24 V I/O supply .............................................................................. 31 2.11.2 115/230 V AC supply ..................................................................... 32 2.12 External 24 V supply ............................................................................... 32 2.13 Distributed I/O units................................................................................. 33 2.13.1 General.......................................................................................... 33 2.13.2 Sensors ......................................................................................... 33 2.13.3 Connection and address keying of the CAN-bus........................... 34 2.13.4 Digital I/O DSQC 328 (optional) .................................................... 37 2.13.5 AD Combi I/O DSQC 327 (optional) .............................................. 39 2.13.6 Analog I/O DSQC 355 (optional) ................................................... 42 2.13.7 Relay I/O DSQC 332 ..................................................................... 48 2.14 Digital 120 VAC I/O DSQC 320 ............................................................... 51 2.15 Gateway (Field bus) units........................................................................ 53 2.15.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350 53 2.15.2 Interbus-S, slave DSQC 351 ......................................................... 56 2.15.3 Profibus-DP, slave, DSQC352....................................................... 59 2.16 Communication ....................................................................................... 61 2.16.2 Ethernet communication................................................................ 64 2.17 External operator’s panel ........................................................................ 66 3 Controller software ........................................................................................... 69 3.1 Introduction................................................................................................ 69 3.1.1 RobotWare CD-ROM....................................................................... 70 3.2 Basic Principles ......................................................................................... 71 3.2.1 Media Pool in the PC....................................................................... 71 3.2.2 System Pool in the PC..................................................................... 72 3.3 Installing new Software ............................................................................. 73 3.3.1 Install cases..................................................................................... 73 3.3.2 Ethernet set-up on PC ..................................................................... 74 3.3.3 RobInstall......................................................................................... 74 3.3.4 How to use RobInstall...................................................................... 74 3.3.5 Create a new Robot Controller image ............................................. 75 3.3.6 Update the Robot Controller image ................................................. 78 3.3.7 Download Robot Controller image................................................... 79 3.3.8 Create Boot Diskettes...................................................................... 80 Product Manual Controller

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3.4

3.5 3.6 3.7 3.8

3.3.9 RobInstall preferences..................................................................... 81 3.3.10 BootImage ..................................................................................... 82 3.3.11 Start window .................................................................................. 82 3.3.12 REBOOT ....................................................................................... 83 3.3.13 BOOT DISKS................................................................................. 83 3.3.14 NETWORK SETTINGS ................................................................. 84 3.3.15 MAIN COMPUTER ........................................................................ 84 3.3.16 I/O COMPUTER ............................................................................ 85 3.3.17 SELECT SYSTEM......................................................................... 85 Perform a Restart ...................................................................................... 86 3.4.1 Reboot (Warm start) ........................................................................ 86 3.4.2 C-start (Erase system)..................................................................... 86 3.4.3 X-start (Restart with the boot application and leaves the current system on a local disk) ...................................................................................... 86 3.4.4 I-Start (Reboot the current system with default settings)................. 87 3.4.5 P-Start (Reinstallation of RAPID language)..................................... 87 Query mode questions .............................................................................. 87 Calibration of the manipulator ................................................................... 88 How to use the disk, Manipulator Parameters........................................... 88 3.7.1 Robot delivered with software installed ........................................... 89 Saving the parameters .............................................................................. 89

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Installation and Commissioning

On-Site Installation

1 On-Site Installation 1.1 Transporting and Unpacking Before starting to unpack and install the robot system, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual. The installation must be done by qualified installation personnel and should conform to all national and local codes. When you have unpacked the cabinet, check that it has not been damaged during transport or while unpacking. Operating conditions: Ambient temperature Ambient temperature Relative humidity

+ 5°C to + 45°C (direct air cooling) + 5°C to + 52°C (Peltier cooling) Max. 95% at constant temperature

Storage conditions: If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25°C and +55°C. 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 the robot system. See chapter 3.1.1 RobotWare CD-Rom.

1.3 Lifting the Cabinet Use the four lifting devices on the cabinet or a fork lift when lifting the controller,

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On-Site Installation

Installation and Commissioning

(see Figure 1). If the controller is supplied without its top cover, lifting devices must not be used. A fork lift truck must be used instead. Min. 60°

A A-A

A

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

1.4 Amount of space required

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On-Site Installation

Air distance to wall

200

200

800

Cabinet extension 800

Option 124

820 Extended cover Option 123

500

250

950 980 *

Lifting points for forklift

500

* Castor wheels, Option 126 70

620

Figure 2The space required for the controller.

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1.5 Bolting the cabinet

400

The cabinet may be secured to the floor using M10 screws (see the footprint drawing below). 720

1.6 Connecting the manipulator to the controller Two cables are used to connect the controller to the manipulator, one for measuring signals 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 connector and a Burndy connector (see Figure 3).

Motor cable XP1

Measurement cable XP2

XS1 XS2

Figure 3Connections on the cabinet wall.

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On-Site Installation

1.7 Mains power connection Before starting to connect the mains, make sure that the other end of the cable is disconnected from the line voltage. The power supply can be connected either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front. The cable connector is supplied but not the cable. The mains supply cables and fuses should be dimensioned in accordance with the rated power and line voltage, see rating plate on the controller. 1.7.1 Connection to the mains switch Remove the left cover plate under the top lid. Pull the mains cable (outer diam. 10.20 mm) through the gland (see Figure 4) located on the left cabinet wall.

XT 26

PE

Cable gland Connector Figure 4Mains connection inside the cabinet.

Connect as below (see also chapter 13, Circuit Diagram.): ◆ Release the connector from the knob by pushing the release buttons located on the side of the connector. ◆ Connect phase - 1 to L1(N.B. Not dependent on phase sequence - 2 to L2 - 3 to L3 - 0 to XT26.N(line neutral is needed only for option 432) - and protective earth to Note! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm. Tighten again after approx. 1 week. Snap the breaker on to the knob again and check that it is fixed properly in the right position. ◆ Tighten the cable gland. ◆ Fasten the cover plate. ◆

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1.7.2 Connection via a power socket You can also connect the mains supply via an optional wall socket of type3x32A, or 4x32A or via an industrial Harting connector (DIN 41 640). See Figure 5. Cable connectors are supplied (option 132 - 134). CEE connector

DIN connector

Figure 5Mains 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: The controller mains section is protected with fuses. ◆ The electrical connections are correct and correspond to the identification plate on the controller. ◆ The teach pendant and peripheral equipment are properly connected. ◆ That limiting devices that establish the restricted space (when utilized) are installed. ◆ The physical environment is as specified. ◆ The operating mode selector on the operator’s panel is in the Manual mode position. When external safety devices are used, check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1X4 (screw terminals on the panel unit) are strapped. ◆

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On-Site Installation

: 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

Auto stop +

A7-A8, B7-B8

X3.11-12, X4.11-12

Auto stop -

A9-A10, B9-10

X3.7-9, X4.7-9

Motor off clamping

A15-A16, B15-16

X1.5-6, X2.5-6

For more information, see 2.7 and 2.7.1.

1.9 Start-up 1.9.1 General Switch on the mains switch on the cabinet. ◆ The robot performs its self-test on both the hardware and software. This test takes approximately 1 minute. If the robot is supplied with software already installed, proceed to pos. 3 below. Otherwise continue as follows (no software installed): - Install the software as described in chapter 3. ◆

A welcome message is shown on the teach pendant display. ◆ To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant. ◆ Update the revolution counters as described in section 1.9.2. ◆ Check the calibration position as described in section 1.9.3. ◆ When the controller with the manipulator electrically connected are powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board. It takes approx. 4 hours to fully charge a computer system battery. After having checked the above, verify that ◆ the start, stop and mode selection (including the key lock switches) control devices function as intended. ◆ each axis moves and is restricted as intended. ◆ emergency stop and safety stop (where included) circuits and devices are functional. ◆ it is possible to disconnect and isolate the external power sources. ◆ the teach and playback facilities function correctly. ◆

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Installation and Commissioning

the safeguarding is in place. ◆ at reduced speed, the robot operates properly and has the capability to handle the product or workpiece, and ◆ in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load. The robot is now ready for operation. ◆

1.9.2 Updating the revolution counter When pressing the enabling device on a new robot, a message will be displayed on the teach pendant telling you that the revolution counters are not updated. When such a message appears, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator (see Figure 10). Examples of when the revolution counter must be updated: - when one of the manipulator axes has been manually moved with the controller disconnected. - when the battery (on the manipulator) is discharged. (it takes 36 hours to recharge the battery with the mains switch on) - when there has been a resolver error - when the signal between the resolver and the measuring panel unit has been interrupted WARNING: Working inside the robot working range is dangerous. Press the enabling device on the teach pendant and, using the joystick, move the robot manually so that the calibration marks lie within the tolerance zone (see Figure 10). When all axes have been positioned as above, the revolution counter settings are stored using the teach pendant, as follows: ◆ Press the Misc. window key (see Figure 6).

7

8

9

4 1

5 2 0

6 3

1 2

P1

P2 P3

Figure 6The Misc. window key from which the Service window can be chosen.

12

◆

Select Service in the dialog box shown on the display.

◆

Press Enter

.

Product Manual Controller

Installation and Commissioning

◆

On-Site Installation

Then, choose View: Calibration. The window in Figure 7 appears. File

Edit

View

Calib

Service Calibration Unit

Status 1(1)

IRB

Not rev. counter update

Figure 7This window shows the status of the revolution counters.

If there is more than one unit connected to the robot, they will be listed in the window. ◆ Select the desired unit in the window, as in Figure 7. Choose Calib: Rev. Counter Update. The window in Figure 8 appears.

Rev. Counter Update! IRB To calibrate, include axes and press OK. Axis

Status 1(6)

X X

1 2 3 4 5 6

X X

Incl

Not updated Not updated Calibrated Calibrated Not updated Not updated

All

Rev. Counter Rev. Counter

Rev. Counter Rev. Counter

Cancel

OK

Figure 8The dialog box used to select axes whose revolution counters are to be updated.

◆

Press the function key All to select all axes, if all axes are to be updated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).

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On-Site Installation ◆

Installation and Commissioning

Confirm by pressing OK. A window like the one in Figure 9 appears.

Rev. Counter Update! IRB The Rev. Counter for all marked axes will be update. It cannot be undone. OK to continue?

Cancel

OK

Figure 9The dialog box used to start updating the revolution counter.

◆

Start the update by pressing OK.

If a revolution counter is incorrectly updated, it will cause incorrect positioning. Thus, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone. ◆

Check the calibration as described in Chapter 1.9.3.

-

+

Figure 10Example of calibration marks on the manipulator.

1.9.3 Checking the calibration position There are two ways to check the calibration position and they are described below. Using the diskette, Controller Parameters: Run the program \ SERVICE \ CALIBRAT \ CAL 6400 on the diskette and follow the instructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check that the calibration marks for each axis are at the same level, see Figure 10. If they are not, the setting of the revolution counters must be repeated. Using the Jogging window on the teach pendant: Open the Jogging window and choose running axis-by-axis. Using the joystick, move the robot so that the read-out of the positions is equal to zero. Check that the calibration marks for each axis are at the same level, see Figure 10. If they are not, the setting of the revolution counters must be repeated. 14

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On-Site Installation

1.9.4 Alternative calibration positions See chapter 15, Repairs Manipulator. 1.9.5 Operating the robot Starting and operating the robot is described in the User’s Guide. Before start-up, make sure that the robot cannot collide with any other objects in the working space.

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Installation and Commissioning

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Connecting Signals

2 Connecting Signals 2.1 Signal classes Power – supplies external motors and brakes. Control signals – digital operating and data signals (digital I/O, safety stops, etc.). Measuring signals – analog measuring and control signals (resolver and analog I/O). Data communication signals – Gateway (Field bus) connection, computer link. Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.

2.2 Selecting cables All cables laid in the controller must be capable of withstanding 70o C. In addition, the following rules apply to the cables of certain signal classes: Power signals Shielded cable with an area of at least 0.75 mm2 or AWG 18. Note that any local standards and regulations concerning insulation and area must always be complied with. Control signals Shielded cable. Measuring signals Shielded cable with twisted pair conductors. Data communication signals Shielded cable with twisted pair conductors. A specific cable should be used for Gateway (Field bus) connections and Ethernet. CAN bus with DeviceNet for distributing I/O units: Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply and two for signal transmission. Note that a separate cable for supply of I/O loads is required. Allen-Bradley Remote I/O: Cables according to Allen-Bradley specification, e.g. “Blue hose”, should be used for connections between DSQC 350 and the Allen-Bradley PLC bus.

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Installation and Commissioning

Interbus-S: Cables according to Phönix specification, e.g. “Green type”, should be used for connections between the DSQC 351 and external Interbus-S bus. Profibus DP: Cables according to Profibus DP specification should be used for connections between the I/O unit DSQC 352 and the external Profibus DP bus. Ethernet: Shielded twisted pair conductors (10 Base T STP)

2.3 Interference elimination Internal relay coils and other units that can generate interference inside the controller are neutralised. External relay coils, solenoids, and other units must be clamped in a similar way. Figure 11 illustrates how this can be done. Note that the turn-off time for DC relays increases after neutralisation, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of the switches that control them. +24V DC

+0V

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

+24V DC, or AC voltage R

C +0V

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

R 100 ohm, 1W C 0.1 - 1 mF > 500 V max. voltage 125 V nominal voltage Figure 11 Examples of clamping circuits to suppress voltage transients.

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Connecting Signals

2.4 Connection types I/O, external emergency stops, safety stops, etc., can be supplied on screw connections or as industrial connectors. Designation X(T)

Screw terminal

XP

Male (pin)

XS

Sockets (female)

2.5 Connections Detailed information about connection locations and functions will be found in chapter 13, Circuit Diagram. 2.5.1 To screw terminal Panel unit and I/O units are provided with keyed screw terminals for cables with an area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one connection. Note! The cable shield must be connected to the cabinet wall using EMC connecting cable 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, or similar. To prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends. 2.5.2 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 12 and Figure 4. In each industrial connector there is space for four rows of 16 conductors with a maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when connecting 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, or similar. To prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends. When contact crimping industrial connectors, the following applies: Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

Using a special crimp tool. Crimp a pin or socket on to each non-insulated conductor. The pin can then be snapped into the actual contact. Push the pin into the connector until it locks. Also, see instructions from connector supplier. A special extractor tool must be used to remove pins or sockets from industrial connectors. When two conductors must be connected to the same pin or socket, both of them are crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.

Operators panel External axes in separate cabinet

Safety signals External conn.

Device Net Mains conn.

I/O connections

External axes in Robot cabinet

Equipment Position switches connection to cabinet Application Interface

Manipulator cables

Figure 12 Positions for connections on the left-hand side of the controller.

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Connecting Signals

2.6 Connection to screw terminal Sockets with screwed connections for customer I/O, external safety circuits, customer sockets on the robot, external supply to electronics.

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

SIO 1, SIO 2

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 X8

24 V supply (2 A fuse)

XT31

115/230 V AC supply

XT21

Locations of socket terminals are shown in Figure 13. See also circuit diagram, “View of control cabinet”, for more details.

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Connecting Signals

Installation and Commissioning X6 (CAN 1.2) X7 (CAN 1.3)

X8 (CAN 2)

Base Connector Unit

X10 (SIO1) X9 (SIO2) X15 (CAN1.1)

Cabinet view from above I/O Units (X4)

Computer system (COM2) XT 31 (24V I/O) Panel Unit Manipulator connections 115/230 VAC

X1-X4 Safety Signals

XT21

Connection to Position switches

XP6

XP5

XP58

XP8

Connection to Customer power Customer signals Figure 13 Terminal locations.

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Connecting Signals

2.7 The MOTORS ON / MOTORS OFF circuit To set the robot to MOTORS ON mode, two identical chains of switches must be closed. If any switch is open, the robot will switch to MOTORS OFF mode. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode. Figure 14 shows an outline principle diagram of the available customer connections, AS, GS and ES . Solid State Switch

LS

Contactor 24V ES 2nd chain interlock

GS TPU En

& EN 1 / 2

Auto Operating mode selector

Drive units

RUN

M

Manual LS = Limit switch AS = Automatic mode safeguard space stop TPU En = Enabling device GS = General mode safeguard space stop ES = Emergency stop EN1/2 = Enable signals from I/O computer and Axis computer respectively RUN = Run command from Main computer

Figure 14 MOTORS ON /MOTORS OFF circuit.

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Connecting Signals

Installation and Commissioning

2.7.1 Connection of safety chains 24 V * X3:12 X4:12

Ext LIM1

24 V

X1:11

K1 0V

12 See 2.7.2 ES1

X3:10 + Opto GS1

isol.

8

-

&

TPU En1

11

RUN

+ Opto AS1 9

-

EN

isol.

Auto1

K1 Interlocking

K2

Man1

External contactors 0V 24 V 0V

X3:3 X4:3

4 4

CONT2

Ext LIM2 X2:11 12

K2 24V

See 2.7.2 ES2

X4:10 8

CONT1

+ Opto isol. -

Drive unit

GS2 M

&

TPU En2

11 +

9

-

Opto isol.

AS2 Technical data per chain Auto2

Man2

X3:7 * X4:7 0V

*) Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply of GS and AS, X3/X4:10,11 is connected to 24 V and X3/X4:8,9 is connected to external 0 V X1-X4 connection tables, see section

2.8.

Limit switch:load max. V drop

300 mA 1V

External contactors: load max. V drop

10 mA 4V

GS/AS load at 24V

25 mA

GS/AS closed “1”

> 18 V

GS/AS open “0”

<5V

External supply of GS/AS

max. +35VDC min. -35VDC

Max. potential relative to the cabinet earthing and other group of signals

300 V

Signal class

Control signals

Figure 15 Diagram showing the two-channel safety chain.

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Connecting Signals

2.7.2 Connection of ES1/ES2 on panel unit t External Internal 24V 0V 24V 0V External

TPU

Cabinet X1:7

X1:9

X1:10 X1:7

E-stop relay

X1:8

24V X1:8

X1:2 ES1 out X1:1 External Internal 0V 24V 0V 24V External

TPU

Cabinet

X2:9

X2:10

X2:1 E-stop relay

0V

X2:8

X2:7

X2:8 X2:6 X2:2 ES2 out

RUN CHAIN X2:1

Technical data ES1 and 2 out max. voltage

120 VAC or 48 VDC

ES1 and 2 out max. current

120 VAC: 4 A 48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A

External supply of ES relays =

min. 22 V between terminals X1:9,8 and X2:9,8 respectively

Rated current per chain

40 mA

Max. potential relative to the cabinet earthing and other groups of signals

300 V

Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply, X1/X2:3 is connected to ext. 24V and X1/

X2:8 is connected to ext. 0V (dotted lines).

Figure 16 Terminals for emergency circuits.

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2.7.3 Connection to Motor On/Off contactors K1 (Motor On/Off 1)

Technical data K2 (Motor On/Off 2)

X3:2 1 X4:2 1

Max. voltage

48V DC

Max. current

4A

Max. potential relative to the cabinet earthing and other groups of signals

300V

Signal class

Control

Figure 17 Terminals for customer use.

2.7.4 Connection to operating mode selector S1.1.x1

Auto1

8 7 6

MAN1

100% (Option) S1.1.x1

Auto2

Max. voltage

48V DC

5

Max. current

4A

4

Max. potential relative to the cabinet earthing and other groups of signals

300V

Signal class

Control

3 2

MAN2

100% (Option)

Technical data

1

Figure 18 Terminals customer use.

2.7.5 Connection to brake contactor Technical data

K3 (Brake)

X4:5 6

Max. voltage

48V DC

Max. current

4A

Max. potential relative to the cabinet earthing and other groups of signals

300V

Signal class

Control

Figure 19 Terminal for customer use.

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Connecting Signals

2.8 External customer connections Customer connections on panel unit: X1- X4.

WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT

EN

X1

X2

1 2

MS NS

3 4 5 6 7 8 9 10 11 12

1 2

3 4 5 6 7 8 9 10 11 12

ES1 ES2 GS1 GS2 AS1 AS2

1 2

1 2

3 4 5 6 7 8 9 10 11 12

3 4 5 6 7 8 9 10 11 12

Chain status LED´s

X3

X4

= jumper Customer connections: X1 - X4, located on the panel unit. The signal names refer to the circuit diagram in chapter 11. X1; 12-pole type Phoenix COMBICON connector. Signal

Terminal no:

Comment

ES1 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

Ext. LIM1:A

11

External limit switch chain 1

Ext. LIM1:B

12

External limit switch chain 1

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Connecting Signals

Installation and Commissioning

X2; 12-pole type Phoenix COMBICON connector. Signal

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 2

ES2 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

X3; 12-pole type Phoenix COMBICON connector.

28

Signal

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

Auto stop plus chain 1

24Vpanel

12

24V to auto stop and general stop

Product Manual S4Cplus

Installation and Commissioning

Connecting Signals

X4; 12-pole type Phoenix COMBICON connector. Signal

Terminal no:

Comment

Ext. MON 2:A

1

Motor contactor 2

Ext. MON 2:B

2

Motor contactor 2

24Vpanel

3

External contactor 2 24V

CONT2

4

External contactor 2

Ext. BRAKE A

5

Contactor for external brake

Ext. BRAKE B

6

Contactor for external brake

0V

7

0V to auto stop and general stop

GS2 -

8

General stop minus chain 2

AS2 -

9

Auto stop minus chain 2

GS2 +

10

General stop plus chain 2

AS2 +

11

Auto stop plus chain 2

24Vpanel

12

24V to auto stop and general stop

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Connecting Signals

Installation and Commissioning

2.9 External safety relay The motor contactors K1 and K2 in the controller can operate with external equipment if external relays are used. Two examples are shown below.

Panel unit

Relays with positive action

X4:4 CONT2 24 V X4:3 Ext MON 2 X4:2

0V

K2 X4:1 X3:2 K1 Ext MON 1

X3:1

24 V

0 V X3:3 CONT1 X3:4

Robot 1

External supply

Robot 2

AS GS

AS GS ES out

(only one channel displayed)

ES out Safety relay

External supply Cell ES To other equipment Safety gate

Figure 20 Diagram for using external safety relays.

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Connecting Signals

2.10 Safeguarded space stop signals According to the safety standard ISO/DIS 11161 “Industrial automation systems safety of integrated manufacturing systems - Basic requirements”, there are two categories of safety stops, category 0 and category 1, see below: The category 0 stop is used when, for safety analysis purposes, the power supply to the motors must be switched off immediately, such as when a light curtain, used to protect against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop. Category 1 is to be preferred, if accepted for safety analysis purposes, such as when gates are used to protect against entry into the work cell. This controlled motion stop takes place within the programmed path, which makes restarting easier. 2.10.1 Delayed safeguarded space stop All the robot’s safety stops are as default category 0 stops. Safety stops of category 1 can be obtained by activating the delayed safeguarded space stop together with AS or GS. A delayed stop gives a smooth stop. The robot stops in the same way as a normal program stop with no deviation from the programmed path. After approx. 1 second the power supply to the motors is shut off. The function is activated by setting a parameter, see User’s Guide, section System Parameters, Topic: Controller.

2.11 Available voltage 2.11.1 24 V I/O supply The robot has a 24 V supply available for external and internal use. The 24 V I/O is not galvanically separated from the rest of the controller voltages. Technical data Voltage 24.0 - 26.4 V Ripple Max. 0.2 V Permitted customer load Max. 7 A Current limit ~ 13,5 ~0A. 24 V I/O available for customer connections at XT 31 see Figure 13. XT.31.2 24 V (via 2 A fuse) XT.31.1 for own fuses. XT.31.4 0 V (connected to cabinet structure).

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Connecting Signals

Installation and Commissioning

2.11.2 115/230 V AC supply The robot has an AC supply available for external and internal use. 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 230 V Permitted customer load Max. 500 VA Fuse size 3.15 A (230 V), 6.3 A (115 V) AC supply is available for customer connections at XT 21 see Figure 13. XT.21.1-5 230 V (3.15 A) XT.21.6-8 115 V (6.3 A) XT.21.9-13 N (connected to cabinet structure)

2.12 External 24 V 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 robot has power on, for example. - When there is a risk that major interference can be carried over into the internal 24 V supply An external supply is recommended to make use of the advantages offered by the galvanic 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 prevent the maximum permitted potential difference in the chassis earth being exceeded. For example, a neutral wire can be connected to the chassis earth of the controller, or some other common earthing point. Technical data: Potential difference to chassis earth: Permitted supply voltage:

Max. 60 V continuous Max. 500 V for 1 minute I/O units 19 - 35 V including ripple panel unit 20.6 - 30 V including ripple

Power Tap A power tap connects the power supply to the trunk line. Power taps differ from device taps in that they contain the following. - A Shottky diode which connects to the power supply V+ and allows for multiple supplies to be connected. - Two fuses or circuit breakers to protect the bus from excess current which could damage the cable and connectors.

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Product Manual S4Cplus

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Connecting Signals

2.13 Distributed I/O units 2.13.1 General Up to 20*) units can be connected to the same controller but only four of these can be installed inside the controller. Normally a distributed I/O unit is placed outside the controller. The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to the other end). The controller can be one of the end points or be placed somewhere in the middle of the chain. For setup parameters, see User’s Guide, section System Parameters, Topic: I/O Signals. *) some ProcessWare reduces the number due to the use of SIM boards. 2.13.2 Sensors Sensors are connected to one optional digital unit. Technical data See Product Specification for controller S4Cplus. The following sensors can be connected: Sensor type Signal level 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)

Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

2.13.3 Connection and address keying of the CAN-bus CAN 1.1 - 1.3. Control cabinet Base connector unit I/O

I/O

I/O

No termination of the last unit

X15 CAN1.1 (Internal I/O)

CAN bus

X6 CAN1.2 X7 CAN1.3

See Figure 22.

I/O

I/O

I/O

I/O

I/O

I/O Termination of last unit

X15, X6, X7

1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O

1. 2. 3. 4. 5.

120 ohm, 1% 0.25 W Metal film

Figure 21 Example of connection of the CAN-bus

34

Product Manual S4Cplus

Installation and Commissioning

u

u u u u

Connecting Signals

CAN 1.1 is used for internal I/O unit mounted inside the cabinet. No terminating resistor is to be mounted on CAN 1.1 regardless of whether there are any I/O units mounted or not. CAN 1.1 is connected to socket X15 on the Base connector unit (see 2.6). If CAN 1.2 is unused there should be a terminating resistor mounted in the X6 socket (exceptional case see below). If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.2 chain. If CAN 1.3 is unused there should be a terminating resistor mounted in the X7 socket (exceptional case see below). If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.3 chain.

Note! If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points. CAN 2 Controller Base connector unit

See Figure 22.

X8 CAN 2

I/O

X8

1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O

1. 0V_CAN 2. CAN_L 3. drain 4. CAN_H 5. 24V_I/O

I/O

1. 2. 3. 4. 5.

I/O

Termination of last unit 120 W, 1% 0.25 W Metal film

24V_CAN must not be used to supply digital inputs and outputs. Instead, they must be supplied either by the 24 V I/O from the cabinet or externally by a power supply unit.

Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

X6 CAN 1.2 (External I/O) X7 CAN 1.3 (External I/O) X8 CAN 2 (External I/O) X15 CAN 1.1 (Internal I/O)

Figure 22 CAN connections on base connector unit.

DeviceNet Connector

Input and ID 12

1

Signal name V- 0V CAN_L DRAIN CAN_H V+ GND MAC ID 0 MAC ID 1 MAC ID 2 MAC ID 3 MAC ID 4 MAC ID 5

X5 Pin 1 2 3 4 5 6 7 8 9 10 11 12

Description Supply voltage GND CAN signal low Shield CAN signal high Supply voltage 24VDC Logic GND Board ID bit 0 (LSB) Board ID bit 1 Board ID bit 2 Board ID bit 3 Board ID bit 4 Board ID bit 5 (MSB)

ID setting Each I/O unit is given a unique address (ID). The connector contains address pins and can be keyed as shown in Figure 23. When all terminals are unconnected the highest address is obtained, i.e. 63. When all are connected to 0 V, the address is 0 (which will cause an error since address 0 is used by the Panel unit). To avoid interference with other internal addresses, do not use addresses 0-9. 36

Product Manual S4Cplus

Installation and Commissioning

Connecting Signals

(0V) 1 2 3 4 5 6 7 8 9 10 11 12 X5 connector address pins address key

1

Example:

2

4

8

16

32

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. Figure 23 Examples of address keying.

2.13.4 Digital I/O DSQC 328 (optional) The digital I/O unit has 16 inputs and outputs divided up into groups of eight. All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. CONNECTION TABLE

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Connecting Signals

Installation and Commissioning

Customer connections: X1 - X4 Status LED’s

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

X1

X3

OUT 9

10

11

12

13

14

15

16

IN

X2 1

1

10

1

10

X4 1

10

10

1

12

X5

CAN-connection, see 2.13.3

X1 Unit function Opto. isol.

Signal name

Pin

Out ch 1

X2 Customer conn.

Signal name

Pin

1

Out ch 9

1

Out ch 2

2

Out ch 10

2

Out ch 3

3

Out ch 11

3

Out ch 4

4

Out ch 12

4

Out ch 5

5

Out ch 13

5

Out ch 6

6

Out ch 14

6

Out ch 7

7

Out ch 15

7

Out ch 8

8

Out ch 16

8

0V for out 1-8

9

0V for out 9-16

9

24V for out 1-8

10*

24V for out 9-16

10*

0V 24V

*) If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program.

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Product Manual S4Cplus

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Connecting Signals

X3 Unit function Opto. isol.

Signal name

Pin

In ch 1

1

In ch 2

2

In ch 3

X4 Customer conn.

Signal name

Pin

In ch 9

1

In ch 10

2

3

In ch 11

3

In ch 4

4

In ch 12

4

In ch 5

5

In ch 13

5

In ch 6

6

In ch 14

6

In ch 7

7

In ch 15

7

In ch 8

8

In ch 16

8

0V for in 1-8

9

0V for in 9-16

9

Not used

10

Not used

10

24 V

0V

Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 Ω) may be used. 2.13.5 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 supplied 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 isolated from the electronics of the controller. The supply to the two analog outputs is generated from 24 V_CAN (with galvanically isolated DC/AC converter). Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. CONNECTION TABLE Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

Customer connections: X1 - X4, X6 Status LED’s

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

X1

X3

OUT 9

10

11

12

13

14

15

IN

X2 1

10

1

10

1

12

X5

CAN-connection, see 2.13.3

X1 Unit function Opto. isol.

6

1

X4

10

1

X6 1

10

16

Signal name

Pin

Out ch 1

X2 Customer conn.

Signal name

Pin

1

Out ch 9

1

Out ch 2

2

Out ch 10

2

Out ch 3

3

Out ch 11

3

Out ch 4

4

Out ch 12

4

Out ch 5

5

Out ch 13

5

Out ch 6

6

Out ch 14

6

Out ch 7

7

Out ch 15

7

Out ch 8

8

Out ch 16

8

0V for out 1-8

9

0V for out 9-16

9

24V for out 1-8

10*

24V for out 9-16

10*

0V 24V

*) If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program.

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Product Manual S4Cplus

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Connecting Signals

X3 Unit function Opto. isol.

Signal name

Pin

In ch 1

1

In ch 2

2

In ch 3

X4 Customer conn.

Signal name

Pin

In ch 9

1

In ch 10

2

3

In ch 11

3

In ch 4

4

In ch 12

4

In ch 5

5

In ch 13

5

In ch 6

6

In ch 14

6

In ch 7

7

In ch 15

7

In ch 8

8

In ch 16

8

0V for in 1-8

9

0V for in 9-16

9

Not used

10

Not used

10

24 V

0V

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

X6 Signal name

Pin

Explanation

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

Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when

Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 Ω) may be used. 2.13.6 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 functions such as controlling gluing equipment etc. 24V to supply external equipment with return signals to DSQC 355. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11. CONNECTION TABLE Customer connections: X1, X3, X 5 - X8 X8-Analog inputs

Bus status LED’s

X7-Analog outputs

X8

X7

S2 S3 X2 X5 X3 Analog I/O

DSQC 355

X5-DeviceNet input and ID connector

ABB flexible Automation

Not to be used

Figure 24 Analog I/O unit

Connector X5- DeviceNet connectors See section 2.13.3 on page 34.

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Product Manual S4Cplus

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Connecting Signals

Connector X7 - Analog outputs. Signal name

X7 Pin

Description

ANOUT_

1

Analog output 1, -10/+10

ANOUT_

2

Analog output 2, -10/+10

ANOUT_

3

Analog output 3, -10/+10

ANOUT_

4

Analog output 4, 4-20mA

Not to be used

5

Not to be used

6

Not 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, 0V

GND

20

Analog output 2, 0V

GND

21

Analog output 3, 0V

GND

22

Analog output 4, 0V

GND

23

GND

24

1

13

12

24

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

Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

Connector X8 - Analog inputs Signal name

44

X8/Pin

Description

ANIN_1

1

Analog input 1, -10/+10 V

ANIN_2

2

Analog input 2, -10/+10 V

ANIN_3

3

Analog input 3, -10/+10 V

ANIN_4

4

Analog input 4, -10/+10 V

Not to be used

5

Not to be used

6

Not 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

+24V out

17

1

17

16

32

+24VDC supply

Product Manual S4Cplus

Installation and Commissioning

Signal name

X8/Pin

Connecting Signals

Description

+24V out

18

+24VDC supply

+24V out

19

+24VDC supply

+24V out

20

+24VDC supply

+24V out

21

+24VDC supply

+24V out

22

+24VDC supply

+24V out

23

+24VDC supply

+24V out

24

+24VDC supply

GND

25

Analog input 1, 0V

GND

26

Analog input 2, 0V

GND

27

Analog input 3, 0V

GND

28

Analog input 4, 0V

GND

29

GND

30

GND

31

GND

32

Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 Ω) may be used Encoder interface unit, DSQC 354 The encoder interface unit provides connections for 1 encoder and 1 digital input. The encoder is used for installation on a conveyor to enable robot programs to synchronise to the motion (position) of the conveyor. The digital input is used for external start signal/ conveyor synchronisation point. Further information User Reference Description Conveyor Tracking. For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11.

Product Manual S4Cplus

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Connecting Signals

Installation and Commissioning

Customer terminals:

ABB Flexible Automation

X20 Conveyor connection

X20

Encoder

CAN Rx CAN Tx MS NS POWER

X5

X5-DeviceNet input and ID connector

DSQC 354

Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A

X3

X3 Not to be used

Device Net connector X5, see section 2.13.3 on page 34 Figure 25 Encoder unit, DSQC 354

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Product Manual S4Cplus

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Connecting Signals

Encoder unit 24 V I/O or external supply 0V 24 V DC 0V Encoder

A B 24 V DC 0V

Sync switch

10-16 not to be used

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Opto Opto

Opto

Opto Opto

Opto

Galvanic insulation

Figure 26 Encoder connections.

The wiring diagram in Figure 26 shows how to connect the encoder and start signal switch to the encoder unit. As can be seen from the illustration, the encoder is supplied with 24 VDC and 0V. The encoder output 2 channels, and the on-board computer, use quadrature decoding (QDEC) to compute position and direction. Connector X20 - Encoder and digital input connections

Product Manual S4Cplus

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Connecting Signals

Input and ID

1

16

Installation and Commissioning

Signal name 24 VDC 0V ENC ENC ENC_A ENC_B DIGIN DIGIN DIGIN Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used

X20 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description 24 VDC supply 0V Encoder 24 VDC Encoder 0 V Encoder Phase A Encoder Phase B Synch switch 24 VDC 0V Synch switch digital input

2.13.7 Relay I/O DSQC 332 16 output relays each with a single Normal Open contact, independent of each other. 16 digital 24V inputs divided into groups of 8. The groups are galvanically isolated. Power supplies to customer switches can be taken either from the cabinet 24 V I/O or from a separate supply. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 11.

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CONNECTION TABLE Customer connections: X1 - X4 Status LED’s

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

OUT 9

10

11

12

13

14

15

16

IN

X1

X2 16

1

16

1

X3

X4 16

1

1

16

1

12

X5

CAN-connection, see 2.13.3

X1 Unit function

Signal name

Pin

Out ch 1a

1

X2 Customer conn.

supply

Signal name

Pin

Out ch 9a

1

Out ch 9b

2

Out ch 1b

2

Out ch 2a

3

Out ch 10a

3

Out ch 2b

4

Out ch 10b

4

Out ch 3a

5

Out ch 11a

5

Out ch 3b

6

Out ch 11b

6

Out ch 4a

7

Out ch 12a

7

Out ch 4b

8

Out ch 12b

8

Out ch 5a

9

Out ch 13a

9

Out ch 5b

10

Out ch 13b

10

Out ch 6a

11

Out ch 14a

11

Out ch 6b

12

Out ch 14b

12

Out ch 7a

13

Out ch 15a

13

Out ch 7b

14

Out ch 15b

14

Out ch 8a

15

Out ch 16a

15

Out ch 8b

16

Out ch 16b

16

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Connecting Signals

Installation and Commissioning

X3 Unit function Opto. isol.

Signal name

Pin

In ch 1

1

In ch 2

2

In ch 3

X4 Customer conn.

Signal name

Pin

In ch 9

1

In ch 10

2

3

In ch 11

3

In ch 4

4

In ch 12

4

In ch 5

5

In ch 13

5

In ch 6

6

In ch 14

6

In ch 7

7

In ch 15

7

In ch 8

8

In ch 16

8

0V for in 1-8

9

0V for in 9-16

9

Not used

10

Not used

10

Not used

11

24 V

0V

Not used

11

Not used

12

Not used

12

Not used

13

Not used

13

Not used

14

Not used

14

Not used

15

Not used

15

Not used

16

Not used

16

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

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2.14 Digital 120 VAC I/O DSQC 320 Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 13. CONNECTION TABLE Customer connections: X1 - X4 Status LED’s

1

2

3

4

5

6

7

8

OUT

MS

IN

NS

OUT 9

10

11

12

13

14

15

16

IN

X1

X2 16

1

16

1

X3

X4 16

1

12

16

1 X5

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CAN connection, see 2.13.3

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X1 Unit function

Opto isol.

52

Signal name

Pin

Out ch 1a

1

Out ch 1b

2

Out ch 2a

X2 Customer conn.

Signal name

Pin

Out ch 9a

1

Out ch 9b

2

3

Out ch 10a

3

Out ch 2b

4

Out ch 10b

4

Out ch 3a

5

Out ch 11a

5

Out ch 3b

6

Out ch 11b

6

Out ch 4a

7

Out ch 12a

7

Out ch 4b

8

Out ch 12b

8

Out ch 5a

9

Out ch 13a

9

Out ch 5b

10

Out ch 13b

10

Out ch 6a

11

Out ch 14a

11

Out ch 6b

12

Out ch 14b

12

Out ch 7a

13

Out ch 15a

13

Out ch 7b

14

Out ch 15b

14

Out ch 8a

15

Out ch 16a

15

Out ch 8b

16

Out ch 16b

16

AC supply

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X3 Unit function Opto isol.

Signal name

Pin

In ch 1a

1

In ch 1b

2

In ch 2a

X4 Customer conn.

Signal name

Pin

In ch 9a

1

In ch 9b

2

3

In ch 10a

3

In ch 2b

4

In ch 10b

4

In ch 3a

5

In ch 11a

5

In ch 3b

6

In ch 11b

6

In ch 4a

7

In ch 12a

7

In ch 4b

8

In ch 12b

8

In ch 5a

9

In ch 13a

9

In ch 5b

10

In ch 13b

10

In ch 6a

11

In ch 14a

11

In ch 6b

12

In ch 14b

12

In ch 7a

13

In ch 15a

13

In ch 7b

14

In ch 15b

14

In ch 8a

15

In ch 16a

15

In ch 8b

16

In ch 16b

16

AC N

2.15 Gateway (Field bus) units 2.15.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350 The RIO-unit can be programmed for 32, 64, 96, or 128 digital inputs and outputs. The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable. Technical data See Allen-Bradley RIO specification. Further information Product Manual S4Cplus

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For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 13. Customer terminals: X8 and X9 X8 Signal name

X9

Pin Remote I/O in

Signal name

Pin

blue

1

1

LINE2 (clear)

2

clear

2

shield

3

shield

3

cabinet ground

4

cabinet ground

4

X5 Device net input and ID connector

Remote I/O out

POWER NS MS CAN Tx CAN Rx NAC STATUS

LINE1 (blue)

X5

X3 Not to be used

DSQC 350

X9

RIO out

X8

RIO in

ABB Flexible Automation

Device Net connector X5, see section 2.13.3 on page 34 Figure 27 RIO-unit

When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradley’s specification. Note! This product incorporates a communications link which is licensed under patents and proprietary technology of Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation. RIO communication concept

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Allen Bradley control system

Robot 1 - 128 in / 128 out Quarter 1 Quarter 2

Robot 2 - 64 in / 64 out Quarter 1

128 in / 128 out

Quarter 3 Quarter 4 Rack ID 12 (example) Rack size 4 Starting quarter 1

64 in / 64 out

Quarter 2

Other systems Quarter 1 Quarter 2

Rack ID 13 (example) Rack size 2 Starting quarter 1

Quarter 3 Quarter 4

Robot 3 - 64 in / 64 out Quarter 3

64 in / 64 out

Quarter 4 Rack ID 13 (example) Rack size 2 Starting quarter 3 Figure 28 RIO communication concept - Principle diagram

The Allen Bradley system can communicate with up to 64 external systems. Each of these systems is called a Rack and is given a Rack Address 0-63. Basically, each robot connected to the Allen Bradley system will occupy 1 rack. Each rack is divided into 4 sections called Quarters. Each quarter provides 32 inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs. A rack may also be shared by 2, 3, or 4 robots. Each of these robots will then have the same rack address, but different starting quarters must be specified. The illustration above shows an example where Robot 1 uses a full rack while robot 2 and robot 3 share 1 rack. The rack address, starting quarter, and other required parameters such as baud rate,

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LED Status etc. are entered in the configuration parameters. The robot may communicate with the Allen Bradley system only, or be used in combination with the I/O system in the robot. For example, the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment via general I/O addresses and the Allen Bradley system only reads the outputs as status signals. 2.15.2 Interbus-S, slave DSQC 351 The unit can be operated as a slave for a Interbus-S system. The Interbus-S slave must have a external power feed so that the Interbus-S net would not shut down if a robot cell is turned off. The 24V power feed must come from outside the control cabinet and be connected to the 2 pin Phoenix connector located on the Interbus-S card’s front panel marked 24V. Technical data See Interbus-S specification. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 17. Unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected data. Width between 1 and 4.

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Customer terminals: see figure below regarding locations.

ABB Flexible Automation

X20

X21 Interbus-S out

X21

RC BA RBDA POWER

Interbus-S

CAN Rx CAN Tx MS NS POWER

X5

DSQC 351

X20 Interbus-S in

X3

X5-DeviceNet input and ID connector

X3 Interbus-S supply

Device Net connector X5, see section 2.13.3 on page 34 Figure 29 Interbus-S, DSQC 351

Communication concept

128 in/128 out Master PLC

64 in/64 out

Robot 1 .3 Word 1.3

Robot 12 Word 4.7.7

Robot 32 Word 8.11 .11

IN

IN

IN

OUT *1

OUT

OUT

*1

Figure 30 Outline diagram.

The Interbus-S system can communicate with a number of external devices, the actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general inputs and outputs. For application data, refer to Interbus-S, International Standard, DIN 19258. Note! That there is a link between pins 5 and 9 in the plug on the interconnection cable which is connected to the OUT connector for each unit. The link is used to inform the Interbus-S unit that more units are located further out in the chain. (The last unit in the chain does not have a cable connected and therefore no link). Product Manual S4Cplus

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Interbus-S IN 1 5

6 9

Interbus-S OUT 5 1

9 6

Interbus-S supply 5

1

Installation and Commissioning

Signal name TPDO1 TPDI1 GND NC NC TPDO1-N TPDI1-N NC NC

X20 Pin 1 2 3 4 5 6 7 8 9

Description Communication line TPDO1 Communication line TPDI1 Ground connection Not connected Not connected Communication line TPDO1-N Communication line TPDI1-N Not connected Not connected

Signal name TPDO2 TPDI2 GND NC +5V TPDO2-N TPDI2-N NC RBST

X21 Pin 1 2 3 4 5 6 7 8 9

Description Communication line TPDO2 Communication line TPDI2 Ground connection Not connected +5VDC Communication line TPDO2-N Communication line TPDI2-N Not connected Synchronisation

Signal name 0 V DC

X3 Pin Description 1 External supply of Interbus-S

NC GND NC + 24 V DC

2 3 4 5

Not connected Ground connection Not connected External supply of Interbus-S

NOTE! An external supply is recommended to prevent loss of fieldbus at IRB power off.

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2.15.3 Profibus-DP, slave, DSQC352 The unit can be operated as a slave for a Profibus-DP system. The Profibus does not need any external power feed. All the robot cells are connected to the trunk cable through a special D-sub connector which works as a very short drop cable. Because of this the profibus will work correctly even if a robot cell is turned off. Technical data See Profibus-DP specification, DIN E 19245 part 3. Further information For setup parameters, see User’s Guide, section System Parameters, Topic: IO Signals. Circuit diagram, see chapter 17.

PROFIBUS ACTIVE

X5 - DeviceNet connector

Profibus

NS MS CAN Tx CAN Rx POWER

X5

X20 Profibus connection

DSQC 352

X20

ABB Flexible Automation

Customer connections

X3 X3 - Power connector

Figure 31 DSQC352, location of connectors

Communication concept 256 in/256 out Master PLC

Robot 1 Word 1:8.3

*1

Robot 1 .7 Word 9:16

128 in/128 out 2 Robot 2 .11 Word 17:24

*1 Figure 32 Profibus-DP communication concept

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The Profibus-DP system can communicate with a number of external devices. The actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs. For application data, refer to Profibus-DP, International Standard, DIN 19245 Part 3. Note! *1 That the Profibus cable must be terminated in both ends.

Profibus-DP 5 1

9 6

Profibus-DP supply 5

1

Signal name Shield NC RxD/TxD-P Control-P GND + 5V DC NC Rxd/TxD-N NC

X20 Pin 1 2 3 4 5 6 7 8 9

Signal name 0 V DC NC GND NC + 24 V DC

X3 Pin 1 2 3 4 5

Description Cable screen Not connected Receive/Transmit data P Ground connection Not connected Receive/Transmit data N Not connected

Description External supply of Profibus-DP Not connected Ground connection Not connected External supply of Profibus-DP

Device Net connector X5, see section 2.13.3 on page 34.

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2.16 Communication 2.16.1

Serial links, SIO

The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see Figure 33). The serial channels are: For permanent use. - SIO1RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 38 400 b/s. - SIO2RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 38 400 b/s. - COM 2 (computer system) RS 232 115 kbps. For temporary use. - COM 1. (Cabinet front) RS 232 115 kb/s Further information - For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. - Circuit diagram, see chapter 13. - Location in the cabinet see Figure 13. Technical data See Product Specification for controller S4Cplus. Separate documentation is included when the option RAP Serial link is ordered.

External computer

Figure 33 Serial channels, SLIP, outline diagram.

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Customer terminals, on base connector board:X10(SIO1) and X9(SIO2), see 2.6. DSQC 504 (D-sub connectors) X10

SIO1

X9

SIO2

Pin

Signal

Socket

Signal

1

TXD

2

TXD N

3

RXD

1

5

1

6

2

RXD

3

TXD

4

DTR

4

RXD N

5

0V

5

0V

6

DSR

6

DATA

7

RTS N

7

DATA N

8

CTS N

8

DCLK

9

DCLK N

1

9

9

5

9 6

Explanation of signals: TXD=Transmit Data, RTS=Request To Send, RXD=Receive Data, CTS=Clear To Send, DTR=Data Terminal Ready, DSR=Data Set Ready, DATA=Data Signals in Half Duplex Mode, DCLK=Data Transmission Clock. COM2 RS232 On computer chassis. Technical data See Product Specification for controller S4Cplus.

Signal

62

Pin

Description

DCD

1

Data Carrier Detect

DSR

6

Data Set Ready

RX

2

Receive Data

RTS

7

Request to Send

TX

3

Transmit Data

CTS

8

Clear to Send

DTR

4

Data Terminal Ready

RI

9

Ring indicator

GND

5

Signal ground

NC

10

Not Connected

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External computer

Figure 34 Connection to COM2 Connector on Computer chassis.

COM1 RS232 Cabinet front (behind service hatch) For temporary use, e.g. connection of Laptop/PC. Technical data See Product Specification for controller S4Cplus.

Signal

Pin

Description

RX

2

Receive Data

TX

3

Transmit Data

GND

5

Signal ground

External computer

Figure 35 Connection behind service hatch.

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2.16.2 Ethernet communication There are two Ethernet channels available. 1. Main computer Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no termination for a cable shield. The cable shield must be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see figure Figure 36. External Computer

Controller Robot 1

Controller Robot 2 etc.

Ethernet HUB Figure 36 Ethernet TCP/IP, Outline diagram.

1

X1

8

Signal name

Pin

Description

TX+

1

Transmit data line +

TX-

2

Transmit data line -

RX+

3

Receive data line +

NC

4

Not connected

NC

5

Not connected

RX-

6

Receive data line -

NC

7

Not connected

NC

8

Not connected

2. I/O computer is used for connection to a Laptop via outlet on cabinet front (behind service hatch) on the controller see Figure 37.

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Ethernet

Figure 37 Connection to Laptop via service outlet.

Further information For setup parameters, see User’s Guide, section System Parameters, Topic: Controller. Circuit diagram, see chapter 13. Separate documentation is included when the option Ethernet services is ordered.

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2.17 External operator’s panel All necessary components are supplied, except for the external enclosure. The assembled panel must be installed in a housing which satisfies protection class, IP 54, in accordance with IEC 144 and IEC 529. M4 (x4) M8 (x4) 45o

Required depth 200 mm

196

193

180 224 240

223

70

62 140

96 Holes for flange

184 200 Holes for operator’s panel

External panel enclosure (Option)

100%

Holes for teach pendant holder

Teach pendant connection

Connection to the controller

90

5 (x2)

155

Figure 38 Required preparation of external panel enclosure.

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67

Connecting Signals

68

Installation and Commissioning

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Installing Program

3 Controller software 3.1 Introduction If the robot controller is ordered with the software installed on delivery, the controller software and settings are stored on the flash disk and the system is ready to use. If the robot controller is ordered and delivered without software or if you want to reconfigure your system, then the Robotware CD-ROM must be installed in the PC. The RobInstall tool is installed at the same time in the PC. This tool is included on the CD-ROM and is used to install the controller software. The controller software can be transferred to the controller flash disk in three ways, namely, via Ethernet (MC or IOC), or by floppy disks, see Figure 39-Figure 40. RobotWare CD-ROM To install RobInstall and System Pack on PC

Create floppy disks to install software

Install software Ethernet:

1. MC 2. IOC Figure 39RobotWare CD-ROM installation.

PC RobInstall

Floppy Disks

Connected to IOC

PC RobInstall MC-Ethernet Network in workshop IOC-Ethernet with delivered boot cable UTP-X Figure 40Controller Software installations.

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The transfer of the controller software to the controller flash disk from Ethernet or floppy disks is executed by an elementary program named Boot Image. This basic program must always be on the flash disk. At start-up, without any controller software installed, Boot Image starts and asks the operator how the RobotWare software should be installed. If the software is already installed, Boot Image is not used. From the flash disk, the controller software is booted to RAM and then cold and warm start can be selected. The installed software can be deleted by X-start and then Boot Image will be active again. 3.1.1 RobotWare CD-ROM To install: Insert the CD in your reader and the install Shield starts automatically and guides you through the install process. The System CD-ROM contains: RobotWare: Controller System Pack for S4Cplus. RobInstall: Robinstall is used to install the software in the robot control system. Test Signal Viewer: Tool (created in LabView) for viewing MotionTest Signals (oscilloscope function) and also for logging these signals. FTP Client: Is used to transport files manually between RobInstall PC and Robot controller flash disk. These actions are carried out in the same way as in a file manager or in Windows Explorer. Note! The CD contains all the System software and should therefore be treated and stored carefully. The manipulator parameter disk contains: Calibration Offsets. When a floppy disk driver or a PC/Laptop is used for booting the system, the disk can be used to install the manipulator parameters. In other cases, there is a label attached to the manipulator on which clear instructions are given for manual loading of the parameters from the TPU. Note! The disk is attached to the manipulator on delivery.

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3.2 Basic Principles 3.2.1 Media Pool in the PC Every release and programs are stored in a media pool directory. Each directory name is an article number ending with the sub-number and with the revision number, for example: Media Pool directory \3HAXaaaa-1.00 rev 00 \3HAXbbbb-1.02 rev 02 \3HAXcccc-1.01 3HAXcccc-1,

(RobotWare System Pack 3HAXaaaa-1, (RobotWare System Pack 3HAXbbbb-1, (ABB Robotics external option program rev 01)

\3XYZdddd-1.00 3XYZdddd-1,

(OEM customer external option program rev 00) (any program directory name is possible)

Figure 41MediaPool Directory.

All the system packs and programs in one pool (mediapooldirpth) must have the correct revision numbers in their directory names. A later revision can be loaded into the program pool, to be added to the old one, without changing the directory name. Two revisions will then exist in the pool.

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3.2.2 System Pool in the PC There must be one system home directory for each controller to be installed, for example: System Pool directory

Figure 42SystemPool Directory

The system home directory must hold two files to make installation of software possible. - key.id (encrypted key file for the actual controller) - program.id

(file with paths to selected programs in the pool)

To install configuration files there must also be a “syspar” directory into which prepared *.cfg files can be preloaded and then included in the software installation procedure. Preparation of S4Cplus software to be installed

Media pool System Pack in \3haxbbbb-1.nn *.* signature no

System pool Ext option in \3haxcccc-1.nn *.* relkey.txt

External option from disk or CD-ROM

System Pack from RW release CD-ROM

Created files key.id program.id

My system \system_n key.id program.id keystr.txt \syspar *.cfg

Inserted key strings are saved in keystr.txt

RobotWare key strings point out the System Pack they belong to and Ext Opt. key string points out added external option programs. All keys must have equal serial no. Figure 43Preparation of software.

Key.id is a newly created file delivered from the key strings, that specifies which options are to be installed from the System Pack and which external option programs are to be installed. 72

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The latest revision of the System Pack and external option programs will be selected as default. When creating a new system to download to the controller via Ethernet or to transfer to a set of diskettes, the pointed System Pack and External Option Programs are copied from the media pool and concatenated into one file that also holds the key.id and the syspar directory. This target file is temporarily stored in the system directory before download or creating diskettes.

3.3 Installing new Software Since most systems are already booted on delivery, the system CD-ROM need only be used a few times, such as when: - Creating a new system - Changing the current system configuration Learn more about creating a new system or changing the current system configuration in the following section. 3.3.1 Install cases The first step is to install RobInstall on your PC. Then you can boot up your controller in several different ways. Floppy Disks: (Floppy Disk Driver is Optional). See section 3.3, Installing new Software for further instructions. Network with direct PC-I/O Computer connection: Insert System CD into your PC and start RobInstall. ◆ Connect patch-cable between the Ethernet connection on the front of the controller and PC/Laptop. ◆ Make sure that the Network protocol is set for TCP/IP properties. See section 3.3, Installing new Software for further instructions. ◆

Network Intranet connection with fix IP: Make C-start or X-start on the S4Cplus controller, see section 3.4.2 or 3.4.3. ◆ Configure IP address from the TPU. ◆ Insert System CD into your PC and start RobInstall. See section 3.3, Installing new Software for further instructions. ◆

Network Intranet connection DHCP ◆

Read Ethernet MAC-id on the Teach Pendant or in delivery document.

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3.3.2 Ethernet set-up on PC These settings must to be implemented to be able to achieve a connection between the PC and the I/O computer. See the numeric value for IP Address, Subnet Mask, and Default Gateway in the figure below.

Figure 44IP Address.

3.3.3 RobInstall Robinstall is used to install the software in the robot control system. With Robinstall you can start, pack, and download software for the S4Cplus robot system. If you have not already installed RobInstall, please Insert the RobotWare CD-ROM in the PC to be able to continue. 3.3.4 How to use RobInstall The following steps describe the possibilities with RobInstall. - Creating a new system. - Updating an existing system. - Downloading an Image file to the controller. - Creating Boot Disks. When RobInstall has been installed, proceed as follows: ◆

74

Click the start button on your PC and choose programs/ABB Robotics and RobInstall. Product Manual Controller

Installation and Commissioning

◆

Installing Program

Choose RobInstall and you will be welcomed by this window, see Figure 45.

Figure 45Start Window.

3.3.5 Create a new Robot Controller image

Figure 46Create a new system.

◆

Choose New to create a new Robot Controller image, with guidance by step-bystep instructions, see Figure 47.

1 2

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Figure 47New Robot Controller image.

Enter a name for the new controller image and select a location for saving it, (see pos. 1.) ◆ Enter the RobotWare key or add from file, see pos. 2. ◆ Press OK and the configured system will be displayed in the next window, see Figure 48. ◆

Press finish if no external options or parameters are to be added or changed. A new controller image will now be created. ◆ Download the controller image to the controller, see section 3.3.7. ◆

Figure 48Add external options.

◆

If external options are to be added, press Next, see Figure 49.

Figure 49Additional key

Enter the key string for the selected option. ◆ If no additional parameters are to be added, press Finish to create the controller ◆

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image. Download the controller image to the controller, see section 3.3.7. ◆ To load additional parameters, press Next, see Figure 50. ◆

1

Figure 50Load Parameter Data.

Press Add to load manipulator calibration data, see pos. 1. ◆ Press Add to load additional parameters, see pos. 2. ◆ If no changes are going to be made to the selected options, press Finish to create the controller image. ◆

Download the controller image to the controller, see section 3.3.7. ◆ To change the option configuration, press Next, see Figure 51. ◆

1

2 Figure 51Change Option Configuration.

◆

To change the Teach Pendant language, robot type, or software options, press Options, see pos. 1.

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If you want the system to boot up in query mode, put a mark in the query mode selection square. For further details of the query mode, see section 3.5. ◆ Press Finish to create the controller image. ◆ Download the controller image to the controller, see section 3.3.7. ◆

3.3.6 Update the Robot Controller image

Figure 52Update image

To update an existing controller image, press Update, see Figure 52. ◆ Select a system in the system list and press OK, see figure Figure 53. ◆

Figure 53Select system.

◆

78

Select a system from the list and press OK. Then follow the instructions in the window Change Option Configuration, see Figure 51. Product Manual Controller

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Installing Program

3.3.7 Download Robot Controller image

Figure 54Download Robot Controller images.

◆

To download the created controller image, press Download, see Figure 54.

Figure 55Select Target System.

Select a target system and press OK, see Figure 55. ◆ Select a system in the list on the left and press OK, see Figure 56. ◆ RobInstall will now create a boot image file and download to the controller. ◆

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Figure 56Select System.

3.3.8 Create Boot Diskettes

Figure 57Create Boot Diskettes.

Press Create Boot Disk, see Figure 57. ◆ Select system in the list on the left and press OK, see Figure 58. ◆

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Figure 58Select system.

RobInstall will now create an image file. ◆ RobInstall will ask you to continue and also inform you how many diskettes the program needs for the image file. ◆ Start loading the image file to diskette by pressing Continue. ◆ Boot up your system as described in section 3.3.1. ◆

3.3.9 RobInstall preferences

Figure 59Customising RobInstall.

To customise RobInstall for new programs and optional products, press Preferences, see Figure 59. ◆ To select a program package, press Select Media Pool, see Figure 60. ◆

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To add a program, press Import Program, see Figure 60.

Figure 60Select Media Pool/ Import Program.

3.3.10 BootImage This program is already installed in the controller and is used to restart the system, to load the system from boot disks, to set or check network settings, or to choose a system from the hard disk drive. The following window displays the start menu. This window will be displayed: 1.When no software is installed at power on. 2. After X.-start. 3.3.11 Start window

Figure 61Start up window.

Reboot ◆ Boot disks ◆ Network settings ◆

◆

82

Select system

- Restart the system - Load the system from diskettes. - Set network settings for main computer or check settings for RobInstall. - Choose a system from the hard disk drive. Product Manual Controller

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Installing Program

3.3.12 REBOOT This menu will be displayed when the Reboot button is pressed or if any settings are changed.

Figure 62Reboot window.

YES ◆ NO ◆

- Restarts the system. - Return to the start window.

3.3.13 BOOT DISKS This window will be shown if the button BOOT DISKS was selected in the start window.

Figure 63Boot disks window.

◆

OK

◆

CANCEL

Product Manual Controller

- Check first that the correct diskette is inserted and that it is OK. The diskette is loaded or asked for again if loading is not possible. - Removes all data loaded previously and returns to the start window.

83

Installing Program

Installation and Commissioning

3.3.14 NETWORK SETTINGS This window will be displayed if the button NETWORK SETTINGS was selected in the start window.

Figure 64Network settings.

Main Computer ◆ I/O Computer ◆ CANCEL ◆

- Show window with network settings for main computer. - Show window with I/O computer and boot-pc settings. - Return to start window.

3.3.15 MAIN COMPUTER This window will be displayed if the button MAIN COMPUTER was selected in the previous window. Note! The data in the window may not be correct. The exact data is enclosed with the system.

Figure 65Main computer window.

◆ ◆ ◆ ◆ ◆ ◆

84

MAC ID Current IP IP Subnet mask Gateway FIX IP

- MC: your ethernet address. - Current IP address defined in the robot’s operating system. - The address that will be defined at reboot. - Only with FIX IP. - Only with FIX IP. - If the controller network uses a fixed IP address. Product Manual Controller

Installation and Commissioning

DHCP ◆ NONE ◆ CANCEL ◆ OK ◆

Installing Program

- If the network uses DHCP. - No IP address. - Return to the start window without changing settings. - The setting is changed and a reboot is required.

3.3.16 I/O COMPUTER This window will be displayed if the button I/O COMPUTER was selected in the previous window.

Figure 66I/O Computer window.

This window contains only information. ◆ I/O Computer settings.- IOC: I/O Computer IP address. ◆ Required RobInstall PC settings- Settings that the PC requires to make RobInstall work. 3.3.17 SELECT SYSTEM The window shows all systems installed on the controller hard disk drive. Select by moving the X to a desired system and press OK. The program will return to the start window if CANCEL is pressed.

Figure 67Select system window.

Configure the DHCP server with the new system and corresponding server name. ◆ Insert the System CD into your PC and start RobInstall. See section 3.3, Installing new Software for further instructions. ◆

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85

Installing Program

Installation and Commissioning

3.4 Perform a Restart 3.4.1 Reboot (Warm start) Select File: Restart Press OK ◆ Advanced Restart: see sections 3.4.2 to 3.4.5. ◆

3.4.2 C-start (Erase system) To install the control program in a robot already in operation, the following method can be used: ◆

Select the Service window

.

Select File: Restart ◆ Then enter the numbers 1 3 4 6 7 9 ◆ The fifth function key changes to C-Start (Cold start) ◆ Press the key C-Start It will take quite some time to implement a Cold start. Just wait until the robot starts the Installation dialog. ◆

Do not touch any key, joystick, enable device, or emergency stop during the cold start until you are prompted to press any key. 3.4.3 X-start (Restart with the boot application and leaves the current system on a local disk) ◆ ◆ ◆ ◆ ◆ ◆

86

Select the Service window Select File: Restart Enter the numbers 1 5 9 The fifth function key changes to X-Start Press the key X-Start Continue by following the text on the teach pendant.

Product Manual Controller

Installation and Commissioning

Installing Program

3.4.4 I-Start (Reboot the current system with default settings) change e.g. language, change IRB type or Options Note! You can only use I-Start for changes if query is selected in Rob/Install. (Only valid for robots within the same family). ◆ ◆ ◆ ◆ ◆ ◆

Select the Service window Select File: Restart Enter the numbers 1 4 7 The fifth function key changes to I-Start Press the key I-Start Continue by following the text on the teach pendant.

3.4.5 P-Start (Reinstallation of RAPID language) ◆ ◆ ◆ ◆ ◆ ◆

Select the Service window Select File: Restart Enter the numbers 2 5 8 The fifth function key changes to P-Start Press the key P-Start Continue by following the text on the teach pendant.

3.5 Query mode questions It is possible to select query mode in RobInstall, if that selection has been made. If query installation is selected in RobInstall, you will be asked whether you wish to boot up in [Silent], [Easy Query] or [Query] mode. Silent If Silent mode is selected, the system will boot up with the system configured in RobInstall. Easy Query If Easy Query is selected, it is possible to:

Product Manual Controller

87

Installing Program

Installation and Commissioning

- Change the Language. - Remove selected options. - Select service or standard mode. Query If Query mode is selected, it is possible to: - Change Robot type (within the same family). - Select DC-link. - Select balancing unit (only for 6400R). - Remove selected options. - <Select language. - Select service or standard mode. The article number of the DC-link used can be found on the unit inside the controller.

Type

Art. no.

Config id

Description

DSQC 345A

3HAB 8101-1

DC0

DC-link

DSQC 345B

3HAB 8101-2

DC1

DC-link

DSQC 345C

3HAB 8101-3

DC2

DC-link

DSQC 345D

3HAB 8101-4

DC3

DC-link, step down

DSQC 358C

3HAB 8101-10

DC2T

DC-link + single drive unit

DSQC 358E

3HAB 8101-12

DC2C

DC-link + single drive unit

For the IRB 6400R, you will also be asked which type of balancing units are used. For identification, please see label attached to the top of the units.

3.6 Calibration of the manipulator Calibrate the manipulator as described in section 1.9.2.

3.7 How to use the disk, Manipulator Parameters The S4Cplus controller does not contain any calibration information on delivery (Robot Not Calibrated shown on the teach pendant). Once the contents of the Manipulator Parameters disk have been loaded into the controller (as in one of the two cases described below), a new parameter backup should be saved on the disk, Controller Parameters. After saving the new parameters on the disk, Controller Parameters, the

88

Product Manual Controller

Installation and Commissioning

Installing Program

Manipulator Parameters disk is no longer needed. 3.7.1 Robot delivered with software installed In this case the basic parameters are already installed. Load the calibration offset values from the disk, Manipulator Parameters. ◆ Select File: Add or Replace Parameter. Do not select Add new or Load Saved Parameters. Press OK. ◆ Save the new parameters as described in section 3.8. ◆

3.8 Saving the parameters See User’s Guide, chapter 12 “System Parameters”, for further information.

Product Manual Controller

89

Installing Program

90

Installation and Commissioning

Product Manual Controller

Maintenance and Repairs CONTENTS Page 1 Introduction ....................................................................................................... 3 1.1 Maintenance Schedule.............................................................................. 3 1.1.1 Changing filters/vacuum cleaning the drive-system cooling............ 4 1.1.2 Changing the battery Unit................................................................ 4 1.1.3 Changing Drive Units....................................................................... 4 1.1.4 Changing Bleeder resistance .......................................................... 5 1.1.5 Changing I/0 Boards........................................................................ 5 1.2 Cooling fans .............................................................................................. 6 1.2.1 Change Drive system fan ................................................................ 6 1.2.2 Computer system, Internal cooling fan ............................................ 6 1.2.3 Computer system, External cooling fan........................................... 7 1.2.4 Main computer, CPU cooling fan ..................................................... 7 1.2.5 Cooling fan DSQC 506 .................................................................... 7 1.2.6 Peltier cooler.................................................................................... 8 1.3 Computer System...................................................................................... 9 1.3.1 Service position ............................................................................... 9 1.3.2 Guiding raits .................................................................................... 9 1.3.3 Connecting cables ........................................................................... 9 1.3.4 Changing Computer back-up battery units ...................................... 9 1.3.5 Check Flash disk capacity ............................................................... 10 1.3.6 Changing Flash disk ........................................................................ 10

Product Manual Controller

1

Maintenance and Repairs CONTENTS Page

2

Product Manual Controller

Maintenance-Repair

Introduction

1 Introduction The robot is designed to be able to work under very demanding conditions with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at specified periodic intervals, as shown in the table below. When handling units and other electronic equipment in the controller, the wrist strap in the controller must be used to avoid ESD damage. The control system is completely encased, which means that the electronics are protected in a normal working environment. In very dusty environments, however, the interior of the cabinet should be inspected at regular intervals. Use a vacuum cleaner if necessary. Change filters in accordance with prescribed maintenance procedures. u Check that the sealing joints and cable glands are really airtight so that dust and dirt are not sucked into the cabinet. u

1.1 Maintenance Schedule Prescribed maintenance

Inspection twice a year

Filter for cabinet cooling.

Maintenance intervals once a year

Xa

4 000 h or 2 years

12 000 h or 3 years

5 years

20 000h or 4 years

10 years

X

Computer System filter. Xb

Battery Unit Cooling Fans Flash Disk

X Xc

a. See 1.2 Changing filters/vacuum cleaning the cabinet cooling. b. See 1.4 Changing the battery unit. c. See 1.5 Checking flash disk capacity.

Product Manual Controller

3

Maintenance Schedule

Maintenance-Repair

1.2 Changing filters/vacuum cleaning the drive-system cooling The article number of the filter is 3HAB 8028-1. u Loosen the filter holder on the outside of the door by moving the holder upwards. u Remove the old filter and install a new one (or clean the old one and re-install it). u When cleaning, the rough surface (on the clean-air side) should be turned inwards. Clean the filter three or four times in 30-40° water with washing-up liquid or detergent. The filter must not be wrung out, but should be allowed to dry on a flat surface. Alternatively, the filter can be blown clean with compressed air from the clean-air side. u If an Computer System filter is not used, the entire cooling duct must be vacuum cleaned regularly.

1.3 Changing filter on Computer cooling fan With straight colling To dismantle Place a screw driver in the track and turn the screw driver until the filter holder come loose see Figure 1. u Change filter. u

Figure 1 changing filter.

To assemble u

4

Assemble in reverse order.

Product Manual Controller

Maintenance-Repair

Maintenance Schedule

1.4 Changing the battery Unit 1.4.1 With Straight Cooling To dismantle Place the computer system in service position see Figure 6. u Remove the four screws to the protection cover on the computer unit see Figure 2. u

Computer Unit

Battery unit

Figure 2 Battery unit (Peltier Cooling).

Pull the battery unit out carefully. u Disconnect the connector and replace the unit. u

To assemble u

Assemble in reverse order.

Product Manual Controller

5

Maintenance-Repair

Maintenance Schedule

1.4.2 With Peltier Cooling To dismantle u

Remove the four screws to the protection cover on the computer unit see Figure 3.

Computer Unit

Battery unit

Figure 3 Battery unit (Peltier Cooling).

Pull the battery unit out carefully. u Disconnect the connector and replace the unit. u

To assemble u

6

Assemble in reverse order.

Product Manual Controller

Maintenance-Repair

Maintenance Schedule

1.5 Changing Flash disk To dismantle Attache the ESD-wrist band. u Loosen the transport locking by turning the screw two laps see Figure 4. u Push the locking washers backwards. u Lift upp an push the two handles together to release the computer unit see Figure 4 and Figure 5. u

Locking washer

Screw (turn two laps) Handles

Figure 4 Transport locking.

u

Push the locking device in the front of the computer unit to the right see Figure 5.

Handles

Lock

Figure 5 Locking device.

u

Pull out the computer unit, make sure that the unit is lock in its end position and turn it to the left.

Product Manual Controller

7

Maintenance-Repair

Maintenance Schedule

Place it in service position or lift it straight upp and place it on a work bench. u Lock the computer unit in service position by placing the puck (placed on the lower left side) on the metal bar. u

Service position

Figure 6 Service position.

Loosen the ten M5 srews and remove the cover from right side of the computer unit see Figure 7. u Loosen the M4 screw and pull out the Flash disk see Figure 7. u Change the Flash disk. u

M5 srew

M4 screw

Flash disk

Figure 7 Flash disk.

To assemble u

8

Assemble in reverse order.

Product Manual Controller

Spare Parts List CONTENTS Page 1 Spare parts for S4Cplus ................................................................................... 2 1.1 Control System M2000.............................................................................. 2 1.1.1 Cabinet Set...................................................................................... 2 1.1.2 Main Cable Set ................................................................................ 2 1.1.3 Operators Panel .............................................................................. 2 1.1.4 Drive System 1400 .......................................................................... 3 1.1.5 Drive System 140 ............................................................................ 4 1.1.6 Drive System 2400 .......................................................................... 5 1.1.7 Drive System 340 ............................................................................ 6 1.1.8 Drive System 4400 .......................................................................... 6 1.1.9 Drive System 640, 840 .................................................................... 7 1.1.10 Drive System 6400 ........................................................................ 7 1.1.11 Drive System 6400PE.................................................................... 8 1.1.12 Drive System Set........................................................................... 8 1.1.13 Connection Set .............................................................................. 8 1.1.14 Teach pendant ............................................................................... 9 1.1.15 Cables to manipulator.................................................................... 10 1.1.16 I/O Interfaces ................................................................................. 13 1.1.17 Computer system .......................................................................... 15 1.1.18 Computer communication.............................................................. 16 1.1.19 Supply system ............................................................................... 16

Product Manual Controller

1

Spare Parts List 1 Spare parts for S4Cplus 1.1 Control System M2000 1.1.1 Cabinet Set Cover control cubicle Cover control cubicle Locking device

1 1

3HAC 1526-1 3HAC 0967-1 3HAC 7137-1

Lock insert 1000-U5 Din 3mm Lock insert EMKA/Daimler Benz Lock insert 3524 Lock insert EMKA Wingknob with locking cyl. 3524

3 3 2 3 1

3HAB 2482-4 3HAB 2482-3 3HAB 7219-2 3HAB 2482-1 3HAB 7862-2

3 2 7 3

3HAB 2425-6 3HAC 0977-1 3HAB 5877-1 3HAB 5878-1

1 1 1 2 1

3HAC 2349-1 3HAB 5171-10 SK 616 003-A SK 616 001-A 3HAB 5171-1 3HAC 6428-1 3HAB 5171-10 SK 616 003-A SK 616 001-A 3HAB 5171-1 3HAB 7818-1 3HAB 5171-1 3HAC 3132-1 opt.191 3HAC 2355-1 opt.193 SK 615 512-1

1.1.2 Main Cable Set Contactor Resistor Auxiliary contact Auxiliary contact 1.1.3 Operators Panel Cam switch Emergency pushbutton Lamp block Contact block Contact block (emergency) Harness control panel 3-pos Emergency pushbutton Lamp block Contact block Contact block (emergency) Actuator transparent Emergency pushbutton Cable harness control panel Cable harness control panel Protective ring Product Manual Controller

1 1 2 1 1 1 1 1 1

2

Spare Parts List Filament lamp Mains: Circuit breaker Fuse

1

5911 069-10

1 3

3HAC 2550-1 3HAC 4803-1

1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1

3HAB 8101-6 3HAB 9271-1 3HAB 8101-8 3HAB 8101-1 3HAB 8101-12 3HAB 8101-3 3HAB 8101-10 3HAC 9174-1 3HAC 6658-1 3HAC 8405-1 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 1616-4 3HAB 9165-1 3HAC 0759-1 3HAC 1616-1 3HAB 9165-1 3HAC 0759-1 3HAC 6161-1 3HAC 6162-1 3HAC 6163-1 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAB 9628-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

1.1.4 Drive System 1400 Modules Drive System Dummy Modul Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Fan Unit , 2 fans Fan with receptacle Int. cable fans 1-2 Fan Unit , 4 fans Fan with receptacle Int. cable fans 1-4 Resistor Unit Brake resistor Bleeder internal conn. Resistor Unit Brake resistor Bleeder internal conn. Transformer Unit T1 Transformer Unit T1 Transformer Unit T1 Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Mains line filter Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1

Product Manual Controller

DSQC 346B DSQC 346G DSQC 345A DSQC 358E DSQC 345B DSCQ 358C

1x47 ohm

4x47 ohm

200-440V 400-500V 475-600V 200-440V 400-500V 475-600V 200-440V 400-500V , 475-600V

3

Spare Parts List 1.1.5 Drive System 140 Modules Drive System Dummy Modul Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Fan Units , 2 fans Fan with receptacle Int. cable fans 1-2 Fan Units , 4 fans Fan with receptacle Int. cable fans 1-4 Resistor Unit Brake resistor Bleeder internal conn. Resistor Unit Brake resistor Bleeder internal conn. Transformer Transformer Unit T1

1 1 1 1 1 1 1 1 2 1 1 4 1 1 2 1 1 4 1

Transformer Unit T1 Transformer Unit T1 Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Main line filter Main line filter Main line filter Main line filter C-jib Switch/Circ B Q1/F1

1 1 1 1

Product Manual Controller

1

1 1 1 1

3HAB 8101-6 3HAB 9271-1 3HAB 8101-8 3HAB 8101-2 3HAB 8101-12 3HAB 8101-3 3HAB 8101-10 3HAC 9174-1 3HAC 6658-1 3HAC 8405-1 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 1616-3 3HAB 9165-1 3HAC 0759-1 3HAC 1616-1 3HAB 9165-1 3HAC 0759-1 3HAC 5601-1 3HAC 6161-1 3HAC 6162-1 3HAC 6163-1 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAC 6684-2 3HAB 9628-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

DSQC 346B DSQC 346G DSQC 345B DSQC 358E DSQC 345C DSQC 358C

2x47 ohm

4x47 ohm

200-440V 400-500V 475-600V 200-440V 400-500V 475-600V

200-440V 400-500V , 475-600V

4

Spare Parts List 1.1.6 Drive System 2400 Modules Drive System Modules Drive System Modules Drive System Dummy Modul Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Fan Units , 2 fans Fan with receptacle Int. cable fans 1-2 Fan Units , 4 fans Fan with receptacle Int. cable fans 1-4 Resistor Unit Brake resistor Bleeder internal conn. Resistor Unit Brake resistor Bleeder internal conn.

1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 1 2 1 1 4 1

3HAB 8101-11 3HAB 8101-7 3HAB 8101-6 3HAB 9271-1 3HAB 8101-8 3HAB 8101-2 3HAB 8101-12 3HAB 8101-3 3HAB 8101-10 3HAC 9174-1 3HAC 6658-1 3HAC 8405-1 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 1616-3 3HAB 9165-1 3HAC 0759-1 3HAC 1616-1 3HAB 9165-1 3HAC 0759-1

DSQC 346E DSQC 346C DSQC 346B

Transformer Unit T1 Transformer Unit T1 Transformer Unit T1 Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Main line filter Main line filter Main line filter C-jib Switch/Circ B Q1/F1

1 1 1 1 1

3HAC 6161-1 3HAC 6162-1 3HAC 6163-1 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAB 9628-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

200-440V 400-500V 475-600V 200-440V 400-500V 475-600V

Product Manual Controller

1 1 1 1

DSQC 346G DSQC 345B DSQC 358E DSQC 345C DSQC 358C

2x47 ohm

4x47 ohm

200-440V 400-500V , 475-600V

5

Spare Parts List 1.1.7 Drive System 340 Modules Drive System Modules Drive System Dummy Modul Drive System Modules Drive System Modules Drive System Modules Drive System Fan unit , 4 fans Fan with receptacle Int.cable fans 1-4 Resistor Unit Brake resistor Bleeder internal conn. Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1

1 1 1 1 1 1 4 1 1 4 1 1 1 1 1 1 1

3HAB 8101-8 3HAB 8101-8 3HAB 9271-1 3HAB 8101-8 3HAB 8101-3 3HAB 8101-4 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 1616-1 3HAB 9165-1 3HAC 0759-1 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

DSQC 346G DSQC 346G

Modules Drive System Modules Drive System Modules Drive System

1 1 1

3HAB 8101-8 3HAB 8101-8 3HAB 8101-8

Modules Drive System Modules Drive System Modules Drive System Fan unit , 4 fans Fan with receptacle Int.cable fans 1-4 Resistor Unit

1 1 1 1 4 1 1

3HAB 8101-3 DSQC 345C 3HAB 8101-12 DSQC 358E 3HAB 8101-10 DSQC 358C 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 1616-1

Brake resistor Bleeder internal conn. Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Mains line filter

4 1 1 1 1 1

3HAB 9165-1 3HAC 0759-1 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAC 7344-1

DSQC 346G DSQC 345C DSQC 345D

200-400V 400-500V 475-600V 200-400V 400-500V , 475-600V

1.1.8 Drive System 4400

Product Manual Controller

DSQC 346G DSQC 346G DSQC 346G

200-400V 400-500V 475-600V 200-400V 6

Spare Parts List Mains line filter C-jib Switch/Circ B Q1/F1

1 1

3HAB 9627-1 3HAB 7429-1

400-500V , 475-600V

1 1 1 1 1 1 1 1 1 1

3HAB 8101-8 3HAB 8101-8 3HAB 9271-1 3HAB 8101-8 3HAC 6164-1 3HAC 6165-1 3HAC 6166-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

DSQC 346G DSQC 346G

Modules Drive System Modules Drive System Modules Drive System

1 1 1

3HAB 8101-13 DSQC 346U 3HAB 8101-13 DSQC 346U 3HAB 8101-13 DSQC 346U

Modules Drive System Modules Drive System Modules Drive System Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1

1 1 1 1 1 1 1 1 1

3HAB 8101-14 3HAB 8101-15 3HAB 8101-16 3HAC 6159-1 3HAC 5138-1 3HAC 6160-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

1.1.9 Drive System 640, 840 Modules Drive System Modules Drive System Dummy Modul Drive System Modules Drive System Transformer Unit T3 Transformer Unit T3 Transformer Unit T3 Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1

DSQC 346G 200-440V 400-500V 475-600V 200-400V 400-500V , 475-600V

1.1.10 Drive System 6400

Product Manual Controller

DSQC 345E DSQC 358F DSQC 358G 200-400V 400-500V 475-600V 200-400V 400-500V , 475-600V

7

Spare Parts List 1.1.11 Drive System 6400PE Electronic Time Relay Mp-capacitor 500VAC Modules Drive System Modules Drive System Modules Drive System Modules Drive System Modules Drive System Fan unit , 4 fans Fan with receptacle Int.cable fans 1-4 Transformer Unit T3 Transformer Unit T3 Transformer Unit T3 Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1

1 1

3HAB 7067-1 4984 211-322

1 1 1

1 1 1 1 1 1

3HAB 8101-8 3HAB 8101-8 3HAB 8101-8 3HAB 8101-3 3HAB 8101-4 3HAC 9173-1 3HAC 6658-1 3HAC 8004-1 3HAC 6164-1 3HAC 6165-1 3HAC 6166-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1

Power supply Bar Bleeder external conn. Ext.cable jib fans

1 1 1

3HAB 8859-1 3HAC 0764-1 3HAC8074-1

Drive system enclosure Transformer cover Maintenance stop

1 1 1

3HAB 8820-1 3HAC 4914-1 3HAC 6519-1

1 1 1 1 1 1 1 1

3HAC 5566-1 3HAC 5564-1 3HAC 6640-1 3HAC 7098-1 3HAC 7272-1 3HAC 2779-1 3HAC 0623-1 3HAC 1803-1

22nF 1000VDC/ DSQC 346G DSQC 346G DSQC 346G DSQC 345C DSQC 345D

200-440V 400-500V 475-600V 200-400V 400-500V , 475-600V

1.1.12 Drive System Set

1.1.13 Connection Set Harness Drive system A1,A2 Cable jib Drive system Harness Drive system A3 Harness Bas ext.ax.cab. Filter unit ext. ax.cab. Harness 1 external axis Harness 2 external axis Harness 3 external axis Ext. axis in seperate Cabinet Product Manual Controller

8

Spare Parts List Modules Drive System Modules Drive System Modules Drive System Modules Drive System Dummy Modul Drive System Power supply Bar Bleeder external conn. Ext.cable jib fans Harness Drive syst A1/A2 Cable jib Drive system Int.cable external Drive Unit Harness pow.ext.axes cab. Harness pow.ext.axes cab. Transformer Unit T2 Transformer Unit T2 Transformer Unit T2 Mains line filter Mains line filter C-jib Switch/Circ B Q1/F1 Serial measurement board Battery 220V fan connection Electronic Time Relay Mp-capacitor

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3HAB 8101-11 3HAB 8101-8 3HAB 8101-11 3HAB 8101-8 3HAB 9271-1 3HAB 8859-1 3HAC 0764-1 3HAB 7433-1 3HAB 9513-1 3HAB 7424-1 3HAC 1919-1 3HAC 2352-1 3HAC 1821-1 3HAC 0751-1 3HAC 0752-1 3HAC 0753-1 3HAC 7344-1 3HAB 9627-1 3HAB 7429-1 3HAB 3700-1 4944 026-4 3HAC 7687-1 3HAB 7067-1 4984 211-322

1 2 1 1 1 1 1 1 1

3HNE 00313-1 3HNE 00188-1 3HAC 4637-1 3HNE 00133-1 3HNM 00032-1 2188 0286-3 2153 0885-3 3HAC 6367-1 3HAB 7290-19 3HAC 0199-1

DSQC 346E DSQC 346G DSQC 346E DSQC 346G

200-440V 400-500V 475-600V

opt.090 22nF 1000VDC/ 500VAC

1.1.14 Teach pendant Prog.Unit w backlight Prog.Unit cable 10m TPU plug Extension Cable for TPU Holder for for TPU Guard/bracket Distance Cable Jib Teach Pendant Multi pol.conn. 19p Washer

Product Manual Controller

9

Spare Parts List 1.1.15 Cables to manipulator Control cable power 7m Control cable power 7m Control cable power 15m Control cable power 15m Control cable power 22m Control cable power 22m Control cable power 30m Control cable power 30m Control cable power 7m

1 1 1 1 1 1 1 1 1

3HAC 2492-1 3HAC 2512-1 3HAC 2529-1 3HAC 2535-1 3HAC 2539-1 3HAC 2560-1 3HAC 2564-1 3HAC 2572-1 3HAC 3382-1

Control cable power 15m

1

3HAC 3383-1

Control cable power 7m

1

3HAC 3386-1

Control cable power 15m

1

3HAC 3387-1

Control cable power 7m Control cable power 15m Control cable power 22m Control cable power 30m Control cable power 7m Control cable power 15m

1 1 1 1 1 1

3HAC 4417-1 3HAC 4417-4 3HAC 4417-5 3HAC 4417-6 3HAC 5548-1 3HAC 5548-2

Control cable power 7m Control cable power 15m Control cable power 22m Control cable power 30m Control cable power 7m

1 1 1 1 1

3HAC 8158-1 3HAC 8159-1 3HAC 8160-1 3HAC 8162-1 3HAC 8182-1

Control cable power 15m

1

3HAC 8182-2

Control cable power 22m

1

3HAC 8182-3

Control cable power 30m

1

3HAC 8182-4

Control cable power 7m Control cable power 15m Control cable power 22m Control cable power 30m Control cable power 7m

1 1 1 1 1

3HAC 8184-1 3HAC 8184-2 3HAC 8184-3 3HAC 8184-4 3HAC 9038-1

Product Manual Controller

340,1400, 2400 640,840,4400,6400PE 340,1400,2400 640,840,4400,6400PE 340,1400,2400 640,840,4400,6400PE 340,1400,2400 640,840,4400,6400PE Prot. Twisted 640,840 4400,6400 Pro. Twisted 640,840 4400,6400 Protection twisted 1400,2400 Protection twisted 1400,2400 6400R 6400R 6400R 6400R 6400 metalbraided 6400 metalbraided 340 int.conn. 340 int.conn. 340 int.conn. 340 int.conn. Foundry IP68 4400,6400S Foundry IP68 4400,6400S Foundry IP68 4400,6400S Foundry IP68 4400,6400S Foundry IP68 6400R Foundry IP68 6400R Foundry IP68 6400R Foundry IP68 6400R Foundry IP68 2400 10

Spare Parts List Control cable power 15m Control cable power 22m Control cable power 30m Control cable signal 7m Control cable signal 7m Control cable signal 15m Control cable signal 15m Control cable signal 22m Control cable signal 22m Control cable signal 30m Control cable signal 30m Control cable signal 7m

1 1 1 1 1 1 1 1 1 1 1 1

3HAC 9038-2 3HAC 9038-3 3HAC 9038-4 3HAC 2493-1 3HAC 2493-1 3HAC 2530-1 3HAC 2530-1 3HAC 2540-1 3HAC 2540-1 3HAC 2566-1 3HAC 2566-1 3HAC 3344-1

Control cable signal 15m

1

3HAC 3345-1

Control cable signal 7m Control cable signal 15m Control cable signal 22m Control cable signal 30m Control cable signal 7m Control cable signal 15m Drive System int.cable Drive System int.cable Drive System int.cable Drive System int.cable Pos. switch cable 7m Pos. switch cable 15m Pos. switch cable 22m Pos. switch cable 30m Pos. switch cable 7m Pos. switch cable 15m Pos. switch cable 22m Pos. switch cable 30m Pos. switch cable 7m Pos. switch cable 15m Pos. switch cable 22m Pos. switch cable 30m Harness in cabinet

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3HAC 7998-1 3HAC 7998-2 3HAC 7998-3 3HAC 7998-4 3HAC 8470-1 3HAC 8470-2 3HAC 6326-1 3HAC 6333-1 3HAC 6340-1 3HAC 6346-1 3HAC 3363-1 3HAC 3364-1 3HAC 3365-1 3HAC 3366-1 3HAC 3378-1 3HAC 3379-1 3HAC 3380-1 3HAC 3381-1 3HAC 4948-1 3HAC 4948-2 3HAC 4948-3 3HAC 4948-4 3HAC 7874-1

Product Manual Controller

Foundry IP68 2400 Foundry IP68 2400 Foundry IP68 2400 640,840,1400,6400PE 340,340r 640,840,1400,6400PE 340,340r 640,840,1400,6400PE 340,340r 640,840,1400,6400PE 340,340r Prot.twisted 640,840 1400,2400,6400PE Prot.twisted 640,840 1400,2400,6400PE 2400,4400,6400,6400S 2400,4400,6400,6400S 2400,4400,6400,6400S 2400,4400,6400,6400S Prot.twisted 4400,6400 Prot.twisted 4400,6400 140,340,1400,2400 4400,6400PE,6400S 640,84 6400 1400 1400 1400 1400 640,840,6400PE 640,840,6400PE 640,840,6400PE 640,840,6400PE 6400 switch axes 2/3 6400 switch axes 2/3 6400 switch axes 2/3 6400 switch axes 2/3

11

Spare Parts List Pos. switch cable 7m Pos. switch cable 15m Pos. switch cable 22m Pos. switch cable 30m Customer cable sign. 7m Customer cable sign. 15m Customer cable sign. 22m Customer cable sign. 30m Cust. Cable power-signal 7m

1 1 1 1 1 1 1 1 1

3HAC 7997-1 3HAC 7997-2 3HAC 7997-3 3HAC 7997-4 3HAC 3346-1 3HAC 3347-1 3HAC 3348-1 3HAC 3349-1 3HAC 3353-1

Cust. cable power-signal 15m

1

3HAC 3354-1

Cust. cable power-signal 22m

1

3HAC 3355-1

Customer harness 30m XP5-R1

1

3HAC 3356-1

Internal Cust. Cable 7m Internal Cust. cable 15m Internal Cust. cable 22m Internal Cust. cable 30m CanBus cable 7m CanBus cable 15m CanBus cable 22m CanBus cable 30m Harness in cabinet Cust. cable power-signal 7m

1 1 1 1 1 1 1 1 1 1

3HAC 3358-1 3HAC 3359-1 3HAC 3360-1 3HAC 3361-1 3HAC 7363-1 3HAC 7363-5 3HAC 7363-6 3HAC 7363-7 3HAC 7849-1 3HAC 8183-1

Cust. cable power-signal 15m

1

3HAC 8183-2

Cust. cable power-signal 22m

1

3HAC 8183-3

Cust. cable power-signal 30m

1

3HAC 8183-4

CanBus cable 7m CanBus cable 15m CanBus cable 22m CanBus cable 30m

1 1 1 1

3HAC 9288-1 3HAC 9288-2 3HAC 9288-3 3HAC 9288-4

Product Manual Controller

2400,4400,6400,6400S 2400,4400,6400,6400S 2400,4400,6400,6400S 2400,4400,6400,6400S 1400,340 vacuum 1400,340 vacuum 1400,340 vacuum 1400,340 vacuum 640,840,2400,4400, 6400PE,6400S 640,840,2400,4400, 6400PE,6400S 640,840,2400,4400 6400PE,6400S 640,840,2400,4400 6400PE,6400S 340 340 340 340 6400 6400 6400 6400 Foundry IP68 2400,4400,6400S Foundry IP68 2400,4400,6400S Foundry IP68 2400,4400,6400S Foundry IP68 2400,4400,6400S Foundry 6400 Foundry 6400 Foundry 6400 Foundry 6400

12

Spare Parts List 1.1.16 I/O Interfaces CanBus cable I/O 1-2 CanBus cable I/O 1-4 I/O external connection Dig. 24VDC I/O Harness Analog I/O Analog I/O Unit, APIP-02 Harness Combi I/O A D Combi I/O Dig. 24VDC I/O Multipole con. X1-X4 10p. Analog I/O Unit, APIP-02 Multipole con. X7, X8. A D Combi I/O Multipole con. X1-X4 10p. Multipole con.X6 6p. Digital 120VAC I/O Multipole con. X1-X4 16p. Digital with relays I/O Multipole con. X1-X4 16p. Ext.cust.conn.harness Link customer connection

1 1 1 1 1 1 1 1 1 1 1 1

Circuit board RIO Multipole con.X8,X9 4p. Interbus-S Unit Multipole con. X3 5p. Profibus DP Slave unit Multipole con. X3 5p. ENC unit Can Bus internal Can Bus cable Male conn. with resistor. Digital I/O Module Multipole con. I/O X5 Multipole con. I/O X10 Multipole con. X1-X4 10p. Bridge connector

1 1 1 1 1 1

Product Manual Controller

1 1

1 1

1 2 1 1 1 1 1

3HAC 7501-1 3HAC 7416-1 3HAC 7660-1 3HAB 7229-1 3HAC 6989-1 3HNE 00554-1 3HAC 6993-1 3HAB 7230-1 3HAB 7229-1 3HAB 9715-1 3HNE 00554-1 3HAB 7342-1 3HAB 7230-1 3HAB 9715-1 3HAB 9664-1 3HAB 7231-1 3HAB 9743-1 3HAB 9669-1 3HAB 9743-1 3HAC 7043-1 3HAC 6384-1 3HNE 00025-1 3HAC 0053-1 3HNE 00006-1 3HAC 1836-1 3HNE 00009-1 3HAC 1836-1 3HAC 1701-1 3HAC 7671-1 3HAC 7404-1 3HAC 7954-1 3HAB 7229-1 3HAB 7178-1 3HAB 7252-1 3HAB 9715-1 3HAB 8335-10

DSQC 328 DSQC 355 DSQC 327 DSQC 328 DSQC 355 DSQC 327

DSQC 320 DSQC 332

DSQC 350 DSQC 351 DSQC 352 DSQC 354

DSQC 328

13

Spare Parts List Metal film resistor Analog I/O Unit, APIP-02 Multipole con. I/O X5 Multipole con. I/O X10 Multipole con.set X7,X8 Bridge connector Metal film resistor A D Combi I/O Module Multipole con. I/O X5 Multipole con. I/O X10 Multipole con. X1-X4 10p. Multopole con. X6 6p. Bridge connector Metal film resistor Dig 120 VAC I/O Module Multipole con. I/O X5 Multipole con. I/O X10 Multipole con. X1-X4 16p. Metal film resistor Bridge connector Dig. with relays I/O Module Multipole con. I/O X5 Multipole con. I/O X10 Multipole con. X1-X4 16p. Metal film resistor Bridge connector Circuit board RIO Multipole con. I/O X5 Multipole con. I/O X10 Multipole con. X6,X9 4p. Bridge connector Metal film resistor Interbus-S Unit Multipole con. I/O X5 Multipole con. I/O X10 Bridge connector Metal film resistor Multipole con. X3 5p. Product Manual Controller

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3HAC 0050-1 3HNE 00554-1 3HAB 7178-1 3HAB 7252-1 3HAB 7342-1 3HAB 8335-10 3HAC 0050-1 3HAB 7230-1 3HAB 7178-1 3HAB 7252-1 3HAB 9715-1 3HAB 9664-1 3HAB 8335-10 3HAC 0050-1 3HAB 7231-1 3HAB 7178-1 3HAB 7252-1 3HAB 9743-1 3HAC 0050-1 3HAB 8335-10 3HAB 9669-1 3HAB 7178-1 3HAB 7252-1 3HAB 9743-1 3HAC 0050-1 3HAB 8335-10 3HNE 00025-1 3HAB 7178-1 3HAB 7252-1 3HAC 0053-1 3HAB 8335-10 3HAC 0050-1 3HNE 00006-1 3HAB 7178-1 3HAB 7252-1 3HAB 8335-10 3HAC 0050-1 3HAC 1836-1

DSQC 355

DSQC 327

DSQC 320

DSQC 332

DSQC 350

DSQC 351

14

Spare Parts List Profibus DP Slave unit Multipole con. I/O X5 Multipole con. I/O X10 Bridge connector Metal film resistor Multipole con. X3 5p. Circuit board ENC-01 Multipole con. I/O X5 Multipole con. I/O X10 Bridge connector Metal film resistor Termin. contact XS6 Termin. contact XS7

1 1 1 1 1 1 1 1 1 1 1 1 1

3HNE 00009-1 DSQC 352 3HAB 7178-1 3HAB 7252-1 3HAB 8335-10 3HAC 0050-1 3HAC 1836-1 3HNE 00065-1 DSQC 354 3HAB 7178-1 3HAB 7252-1 3HAB 8335-10 3HAC 0050-1 3HAC 7926-1 3HAC 7933-1

1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3HAC 7148-1 3HAC 3617-1 3HAC 3616-1 3HAC 3619-1 3HAC 8848-1 3HAC 3619-1 3HAC 5475-1 3HAC 6375-1 3HAC 4296-1 3HAC 5393-2 3HAC 7927-1 3HAC 7927-5 3HAC 7520-1 3HAC 7055-1 3HAC 7155-1 3HAC 6328-1 3HAC 6320-1 3HAC 6378-1 3HAC 6378-1 3HAC 6658-1 2158 0132-176 3HAC 6655-1 3HAC 6658-1

1.1.17 Computer system Assembly Comp. Enclosure Backplane Main computer Axis computer I/O computer Axis computer Card Bracket PCI PC-harness Power Supply Comp. Battery Unit Flash disc 64MB Flash disc 128MB Bracket Flash Adapter Straight cooling IP Protection, Fan Fan Net Cable jib. Power Sup.B.P Harddisc harness Fan with recptacle Grating Fan Unit Fan with receptacle Product Manual Controller

DSQC 501 DSQC 500 DSQC 503 DSQC 522 DSQC 503

DSQC 505 DSQC 508 DSQC 518 DSQC 518 DSQC 507 DSQC 517 opt.472

15

Spare Parts List Fan holder Grating Cable jib. Ext.comp.fans

1 1 1

3HAC 5220-1 2158 0132-176 3HAC 6168-1

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3HAC 6232-1 3HAB 2480-1 3HAC 6157-1 3HAC 7255-1 3HAC 7273-1 3HAC 8083-1 3HAC 7331-1 3HAC 7239-1 3HAC 6717-1 3HAC 7461-1 3HAA 3003-29 3HAC 7433-1 3HAC 7855-1 3HAC 7290-1 3HAB 9621-4 3HAC 8314-1 3HAC 8315-1 3HAC 7896-1 3HAC 7862-1 3HAC 5689-1 3HAC 5498-1 3HAC 5497-1 3HAC 5518-1 3HAC 5687-1 3HAC 7518-1 3HAC 6546-1 3HAC 5497-1 3HAC 7419-1

1 1

3HAC 4297-1 3HAC 5319-1

1.1.18 Computer communication Disc drive unit Floppy disc drive Floppy signal/supply cable Inner floppy bracket Cover Floppy cover Floppy bracket Floppy cover Shaft Torsion spring Lock washer Gasket for floppy cover Service set Connector cover Outlet 2-p w. earth term. Outlet set Common outlet set Computer outlet Power Supply Comp. Base Conn Unit Bus cable DB44 Bus cable DB25 Bus cable DB15 Panel Unit Expansion set Axis Conn Unit Bus cable DB25 Expansion cable jib

opt.410 opt.412 opt.411 opt.411,412

DSQC 504

DSQC 509 DSQC 513

1.1.19 Supply system Power supply Proc Spring Product Manual Controller

DSQC 506

16

Circuit Diagram CONTENTS Page 1 Controller, diagram 3HAC 5582-2 Rev.0 .................................................................. 1-91

Product Manual Controller

Installation and Commissioning CONTENTS Page 1 Transporting and Unpacking ........................................................................... 3 1.1 Stability / risk of tipping.............................................................................. 3 1.2 Parameter diskette .................................................................................... 3 2 On-Site Installation ........................................................................................... 5 2.1 Lifting the manipulator ............................................................................... 5 2.1.1 Manipulator...................................................................................... 6 2.2 Suspended mounting ................................................................................ 7 2.2.1 Changing system parameters for suspended or tilted mounting ..... 7 2.2.2 Defining the parameters .................................................................. 8 2.3 Stress forces ............................................................................................. 9 2.3.1 Stiffness........................................................................................... 9 2.3.2 Forces.............................................................................................. 9 2.4 Amount of space required ......................................................................... 11 2.5 Manually releasing the brakes................................................................... 14 2.6 Restricting the working space ................................................................... 15 2.7 Mounting holes for equipment on the manipulator .................................... 15 2.8 Loads......................................................................................................... 16 3 Customer connections on manipulator .......................................................... 17

Product Manual IRB 140

1

Installation and Commissioning CONTENTS Page

2

Product Manual IRB 140

Installation

Transporting and Unpacking

1 Transporting and Unpacking NB: Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the User’s Guide and Product manual. Note ! The installation must be done by qualified installation personnel and should conform to all national and local codes. When you have unpacked the robot, check that it has not been damaged during transport or while unpacking. Operating conditions: Ambient temperature: +5° to + 45° C (manipulator) 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 dry area at an ambient temperature between -25°C and +55°C. When air transport is used, the robot must be located in a pressure-equalized area. The net weight of the manipulator is approximately: 100 kg

1.1 Stability / risk of tipping When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipulator to tip over.

1.2 Parameter diskette The parameter diskette is delivered with the manipulator in a box, and should be copied (in a PC) before it is used. Never work with the original diskettes. When you have made copies, store the originals in a safe place. Do not store diskettes inside the controller due to the high temperatures there.

Product Manual IRB 140

3

Transporting and Unpacking

4

Installation

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

2 On-Site Installation 2.1 Lifting the manipulator Position the manipulator as shown in the figure below. Attach two straps of equal length under the lower arm. Never walk under a suspended load

Figure 1 Lifting the manipulator using a traverse crane.

Product Manual IRB 140

5

On-Site Installation

Installation and Commissioning

2.1.1 Manipulator The manipulator must be mounted on a level surface with the same hole layout as shown in Figure 2. The levelness requirements of the surface are as follows: 0.5 . ∅ 13

39

80

12

1

155 39

∅ 25H8 (2x) ∅ 0,25 A

45°

A

A-A

B-B

A

180

∅ 13

B

B

180

C Axis 1

A

Figure 2 Bolting down the manipulator.

The manipulator is bolted down by means of three M12 bolts. Suitable bolts: M12 8.8 Suitable washer: Steel Do=24 mm Di=13.4 mm T=2.5 mm Tightening torque: 85 Nm Two guide bushings, ABB art. no. 3HAC9519-1, can be fitted to the two rear bolt holes, to allow the same robot to be re-mounted without having to re-adjust the program. Note! When the robot is going to mounted in a tilted or suspended position, the guide bushings must be used to secure the bolted joint. When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in Chapter 2.3 Stress forces . 6

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

2.2 Suspended mounting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting. With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved. 2.2.1 Changing system parameters for suspended or tilted mounting Initially the system is configured for mounting on the floor, without leaning. If the robot is mounted at any other angle, the system parameter “gravity beta” must be updated. Gravity beta specifies the robot’s mounting angle expressed in radians. Note! It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Note! Incorrect definition of mounting angle (gravity beta) will result in: Overloading the mechanical structure. ◆ Lower path performance and path accuracy. ◆ Some S4 functions will not work properly: - Collision Detection ◆

- Load Identification Angles and values. The Parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 45°. Example: gravity beta = 45° x 3.141593/180 = 0.785398 radians. Examples of different mounting angles see Figure 3. Examples of Position

Mounting Angle

Gravity Beta

Floor (pos 1)

0°

0.000000 (Default)

Wall (pos 2)

90°

1.570796

Ceiling (pos 3)

180°

3.141593

Tilted (pos 4)

45°

0.785398

Product Manual IRB 140

7

On-Site Installation

Installation and Commissioning

Note! The robot can only be tilted forward or backward. The Y direction of the robot’s base frame must always be horizontal, see pos 4 in Figure 3.

(Example of tilted mounting 45°) Z 45°

Y pos 4

se Ba

pos 1

am Fr

X

e

180°

90° pos 2

pos 3

Figure 3 Mounting angle.

2.2.2 Defining the parameters • Choose Topics: Manipulator. • Choose Types: robot. • Select (master) and press Enter

.

• Select the desired parameter “gravity beta” and change its value. • Press OK to confirm.

8

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

2.3 Stress forces 2.3.1 Stiffness The stiffens of the foundation must be designed to minimise the influence on the dynamic behaviour of the robot. TuneServo can be used for adapting the robot tuning to a non-optimal foundation. 2.3.2 Forces

Force

Endurance load (In operation)

Max. load (Emergency stop)

Fxy (upright/suspended)

± 1300 N

± 3200 N

Fxy (wall)

± 2200 N

± 3900 N

Fz (upright)

-1000 ± 1000 N

-1000 ± 2000 N

Fz (suspended)

-2800 ± 1000 N

+1000 ± 2000 N

Fz (wall)

± 1000 N

± 2200 N

Mxy

± 1300 Nm

± 2200 Nm

Mz

± 300 Nm

± 750 Nm

Torque

Fxy and Mxy are vectors that can have any direction in the xy plane.

Product Manual IRB 140

9

On-Site Installation

Installation and Commissioning

Y X Z

Y

X Z

Z

X Y Figure 4 The directions of the stress forces.

10

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

2.4 Amount of space required The amount of space and working area required to operate the manipulator is illustrated in Figure 5 and Figure 6. The working range for axis 1 is +/- 180°. NB: There are no software or mechanical limits for the working space under the base of the manipulator.

595 380

65

70

360

810

352

175

201

273

70 448

CL

CL axis 1

R244 Minimum turning radius

402

123

Figure 5 The amount of space required for the manipulator.

Product Manual IRB 140

11

On-Site Installation

Installation and Commissioning

Pos 1

Z Pos 0

Pos 6

1120

Pos 7 1243

Pos 2 Pos 8

Pos 3 Pos 5

X

28

151

Pos 4*)

70

255 184

486

324

670

810 CL

* Pos 4 varies with the angle of axis 1 as shown in the drawing to the left R540

Pos. 4

20°

R2 55

Figure 6 Working area.

12

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

+180°

R8 10

R3 24

4 24 R

-180°

* The default working range for axes 4 and 6 can be extended by changing parameter values in the software.

Figure 7 Working range axes 4 and 6.

Product Manual IRB 140

13

On-Site Installation

Installation and Commissioning

2.5 Manually releasing the brakes All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable engagement of the brakes. The voltage supply should be connected to the connector on the control cable or the Burndy connector in the manipulator base under the cover. (see Figure 8).

Harting connector: XP1

Burndy connector: R1.MP4-6 1 4 7

2

3

5

6

8

91

10

11

12

13

14

15

0V + 24 V DC B14 (0V) B16 (24V)

Figure 8 Connection of external voltage to enable engagement of the brakes.

Note! Be careful not to interchange the 24 V- and 0 V pins. In they are mixed up, damage can be caused to a resistor diode and to the system board. External power must be connected as shown in Figure 8. If the power is incorrectly connected, all the brakes can be released causing simultaneously movement of all axes. When the controller or the voltage supply is connected as illustrated above, the brakes can be engaged using the push-button on the manipulator, (see Figure 9). WARNING: Be very careful when releasing the brakes. The axes become activated very quickly and may cause damage or personal injury.

Brake release button

Figure 9 Location of the brake release button.

14

Product Manual IRB 140

Installation and Commissioning

On-Site Installation

2.6 Restricting the working space Limiting the working space using software is described in the chapter System Parameters in the User’s Guide.

2.7 Mounting holes for equipment on the manipulator Never drill a hole in the manipulator without first consulting ABB Flexible Automation. 51

62

Mounting holes for equipment M5 Depth 7.5 (2x)

70

74

Mounting holes for equipment M5 Depth 7.5 (2x)

Figure 10 Mounting holes for customer equipment.

+0.012 -0 H7

+0.033

M6 (4x)

D=25 -0

R=20

h8

B

+0 -0.039

∅ 0.05

B

9

D=50

45

D=6

H8

A o

A 90o (4x)

6

A-A Figure 11 The mechanical interface (mounting flange).

Product Manual IRB 140

15

On-Site Installation

Installation and Commissioning

2.8 Loads Regarding load diagram, permitted extra loads (equipment), and locations of extra loads (equipment), see the chapter for Technical specification in the Product Specification IRB 140. The loads must also be defined in the software, see the User´s Guide.

16

Product Manual IRB 140

Installation and Commissioning

Connections

3 Customer connections on manipulator Connections: R1/4” in the upper arm housing and R1/4” at the base. Max. 8 bar. Inner hose diameter: 6.5 mm. For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling and one FCI UT07 14 12 SH 44N connector on the upper arm housing. Number of signals: 12 signals 60 V, 500 mA.

R2.CS

Figure 12 Location of customer connections.

To connect to power and signal conductors from the connection unit to the manipulator base and on the upper arm, the following parts are recommended: Connector R2.CS. Signals, on upper arm. (Regarding Pos see Figure

13)

Pos

Name

ABB art. no.

Type

Comments

1

Socket connector

3HAC 7446-3

UT 07 14 12 SH 44N

Burndy

2

Socket

See below

3

Pin connector 12p

3HAC 7907-1

UTO 61412 P45N

4

Pin connector 12p

3HAC 7455-3

UTO 61412 P45N

5

Pin

See below

6

Adaptor

5217 1038-3

7

Shrinking hose

3HAA 2614-2

Bottled shaped

8

Shrinking hose

5217 1032-4

Angled

Product Manual IRB 140

UTG 14 ADN

Burndy

17

Connections

Installation and Commissioning

Name

ABB part no.

Type

Comments

Pin

5217 649-72 5217 649-25 5217 649-70 5217 649-3 5217 649-68 5217 649-10 5217 649-31

24/26 24/26 20/22 20/22 16/18 24/26 16/20

Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Ground Burndy Ground

Socket

5217 649-73 5217 649-26 5217 649-71 5217 649-69

24/26 24/26 20/22 16/18

Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Machine tooling

6

7

4, 5

1, 2

3, 5

Figure 13 Burndy connector

18

Product Manual IRB 140

Maintenance CONTENTS Page 1 Maintenance ...................................................................................................... 1.1 Maintenance Intervals ............................................................................... 1.2 Instructions for Maintenance ..................................................................... 1.3 Changing and checking the oil in gearboxes 5 and 6................................ 1.3.1 Oil in gearboxes 5-6 ........................................................................ 1.3.2 Changing the battery in the measuring system ...............................

Product Manual IRB 140

3 3 4 4 5 5

1

2

Product Manual Controller

Maintenance 1 Maintenance The robot is designed to be able to work under very demanding circumstances with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at given periodical intervals, see the table below. ◆ The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents, that can damage the sealing joints, bearings, lacquer or cabling, must not be used.

1.1 Maintenance Intervals Prescribed maintenance

Running Control

Maintenance intervals Every 2000 h or 6 months

MANIPULATOR

Mechanical stop axis 2-3

Every 4000 h or 1 year

Others

X1 3 years2

Drive Belts Cable Harnesses

X3

Gears 1-4

Maintenance-free

Gears 5 and 6 Change oil

3 years4

Measuring system Change battery

3 years5

1. Check that the rubber cushion is in place and undamaged. 2. Check the drive belts, change if damaged 3. Inspect all visible cabling, Change if damaged. 4. Oil change every 3rd year, see section 1.3 5. Change battery, see section 1.3.2.

Product Manual IRB 140

3

Maintenance 1.2 Instructions for Maintenance 1.3 Changing and checking the oil in gearboxes 5 and 6 Draining the gearbox: Run the upper arm to a horizontal position and turn axis 4 to the calibration position. ◆ Remove both the oil plugs in the wrist see Figure 1. ◆

Turn axis 4 through 90o so that the oil plug on the side of the wrist is pointing downwards. ◆ Drain the gearboxes 5 and 6 from oil. ◆

Then turn axis 4 a further 90o. ◆ Let the remaining oil run out through the hole on the tilt housing (axis 5). ◆

New oil is refilled as follows: Run the upper arm to a horizontal position and turn axis 4 to the calibration position. ◆ Fill oil in the hole located on the tilt housing (axis 5) until the oil reaches up to the hole located on the side of the wrist (see Figure 1). ◆

NOTE! If the robot is mounted in suspension, the wrist should be turned 180o. ◆ Put the oil plugs back in the wrist. Volume: 2 ml (0.00053 US gallon) ◆

Oil plugs axes 5 and 6

Figure 1 Changing oil axes 5 and 6.

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Product Manual IRB 140

Maintenance 1.3.1 Oil in gearboxes 5-6 ABB article no. 1171 2016-604 corresponds to: Optimol: Esso: BP: Texaco:

BM 320 Spartan EP 320 Energol GR-XP 320 Meropa 320

Castrol:Alpha SP 320 Klüber:Lamora 320 Shell:Omala Oil 320

Volume of gearbox 4:

0.20 l (0.4 US gallon)

Volume of wrist

0.25 l (0.032 US gallon)

1.3.2 Changing the battery in the measuring system The battery is located inside the base under the flange cover, see Figure 2. The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4. The battery must never be just thrown away; it must always be handled as hazardous waste. ◆ Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after changing the battery.) ◆ Remove the flange cover by loosen the screws and turn the cover carefully out from left to right, see Figure 2. Note ! When doing this operation a wrist band must be used for ESD protection (ESD= Electrostatic Discharge). ◆

Remove the two screws holding the serial measurement board. Push the unit to the side and remove it backwards. All cables and connectors must remain intact.

Note ! The cable harness must be treated with great care. ◆ ◆ ◆ ◆ ◆

Loosen the battery terminals from the serial measuring board and cut the clasps that keep the battery unit in place. Install a new battery with two clasps and connect the terminals to the serial measuring board. Refit the serial measurement board and make sure that the seals are undamaged and in place before mounting the flange cover. Connect the battery connector. The Ni-Cd battery takes 36 hours to recharge. The mains supply must be switched

Product Manual IRB 140

5

Maintenance on during this time.

Flange cover

Figure 2 The battery is located inside the base under the flange cover.

Alternative battery As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed. The lithium battery needs no charging and for that reason it has a blocking diode which prevents charging from the serial measurement board. The advantage of a lithium battery is the longer service life, which can be up to 5 years, compared to a Ni-Cd battery, which has a max. service life of 3 years. There are two types of lithium battery available: - a 3 cell battery, art. no. 3HAB 9999-1 - a 6 cell battery, art. no. 3HAB 9999-2 The service time of the lithium battery depends on how frequently the user switches off the mains power. The estimated max. life time in years for the different types of lithium battery and the recommended exchange intervals are shown below: User type:

Replace 3 cell:

Replace 6 cell:

1. Vacation (4 weeks) power off

every 5 years

every 5 years*

2. Weekend power off + user type 1

every 2 years

every 4 years

3. Nightly power off + user type 1 and 2

every year

every 2 years

* Because of material ageing, the maximum service life must be limited to 5 years. Voltage of batteries, measured at power off: Min.

Max.

Ni-Cd

7.0 V

8.7 V

Lithium

7.0 V

-

Replacing the battery is described in the first section of this chapter.

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Product Manual IRB 140

Repairs CONTENTS Page 1 General Description .......................................................................................... 3 1.1 Instructions for reading the following sections........................................... 4 1.2 Caution ...................................................................................................... 5 1.3 Fitting new bearings and seals.................................................................. 5 1.3.1 Bearings .......................................................................................... 5 1.3.2 Seals................................................................................................ 6 1.4 Instructions for tightening screw joints ...................................................... 7 2 Axis 1.................................................................................................................. 9 2.1 Changing the motor of axis 1 .................................................................... 9 2.2 Changing the gearbox ............................................................................... 10 2.3 Replacing the mechanical stop ................................................................. 11 3 Axis 2.................................................................................................................. 13 3.1 Changing the motor of axis 2 .................................................................... 13 3.2 Changing the gearbox ............................................................................... 14 3.3 Dismantling the lower arm......................................................................... 14 3.4 Changing the support bearing in the lower arm ........................................ 15 4 Axis 3.................................................................................................................. 17 4.1 Changing the motor of axis 3 .................................................................... 17 4.2 Gear box axis 3 ......................................................................................... 18 4.3 Changing the drive belt ............................................................................. 18 5 Upper arm, axes 4-6 .......................................................................................... 21 5.1 Changing the motors ................................................................................. 21 5.1.1 Motor axis 4 ..................................................................................... 21 5.1.2 Motor axes 5 and 6.......................................................................... 22 5.2 Dismantling the wrist ................................................................................. 24 5.3 Exchanging the upper housing, with motor units....................................... 25 5.4 Changing the driving belt on axes 5 and 6 ................................................ 26 5.5 Dismantling the complete upper arm......................................................... 27 5.6 Measuring the play on wrist....................................................................... 27 5.6.1 Axis 5............................................................................................... 27 5.6.2 Axis 6............................................................................................... 28

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1

Repairs CONTENTS Page 6 Cabling and Serial Measuring board............................................................... 29 6.1 Changing the serial measuring board ....................................................... 29 6.2 Cabling axes 1 and 2................................................................................. 29 6.3 Changing the cabling for axes 3, 4, 5 and 6.............................................. 29 7 Motor Units ........................................................................................................ 33 8 Calibration ......................................................................................................... 35 8.1 General...................................................................................................... 35 8.2 Checking the calibration position............................................................... 35 8.3 Fine calibration procedure on the teach pendant ...................................... 36 8.4 Fine calibration .......................................................................................... 38 8.4.1 Axis 1............................................................................................... 38 8.4.2 Axes 2 - 6 ........................................................................................ 39 8.5 Updating revolution counter ...................................................................... 43

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Product Manual IRB 140

Repairs

General Description

1 General Description The industrial robot system comprises two separate units: the control cabinet and the manipulator. Servicing the mechanical unit is described in the following sections. Lifting and turning the manipulator are described in the Chapter entitled, Installation and commissioning. When servicing the manipulator, it is helpful to service the following parts separately: - The Electrical System - The Motor Units - The Mechanical System The Electrical System is routed through the entire manipulator and is made up of two main cabling systems: the power cabling and signal cabling. The power cabling feeds the motor units of the manipulator axes. The signal cabling feeds the various control parameters, such as axis positions, motor revs, etc. The AC Motor Units provide the motive power for the various manipulator axes by means of gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 3 minutes during both automatic and manual operation. The manipulator has 6 axes which makes its movements very flexible. Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion. Axis 3 raises the upper arm of the manipulator. Axis 4, rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and 6. These axes form a cross and their motors are located at the rear of the upper arm. Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools on the tip of the wrist in the turn disc. The signals to/from the tool are supplied via internal customer connections. Note! that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards, cabling, resolver unit). When any type of maintenance work is carried out, the calibration position of the manipulator must be checked before the robot is returned to the operational mode. Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot.

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General Description

Repairs

1.1 Instructions for reading the following sections The subsequent sections describe the type of on-site maintenance that can be performed by the customer’s own maintenance staff. Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB Flexible Automation for service. Calibration: The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the motor and feedback unit are disconnected, when a resolver error occurs, or when the power supply between a measurement board and resolver is interrupted. This procedure is described in detail in Calibration Chapter 8 . Any work on the robot signal cabling may cause the robot to move to the wrong positions. After performing such work, the calibration position of the robot must be checked as described in Calibration Chapter 8 . Tools: Two types of tools are required for the various maintenance jobs. It may be necessary to use conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on the type of servicing. Conventional tools are not discussed in this manual, since it is assumed that maintenance staff have sufficient basic technical competence. Maintenance jobs which require the use of special tools are, on the other hand, described in this manual. Foldouts: The chapter on spare parts comes with a number of foldouts which illustrate the parts of the robot. These foldouts are provided in order to make it easier for you to quickly identify both the type of service required and the make-up of the various parts and components. The item numbers of the parts are also shown on the foldouts. In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference is made to a foldout, other than that specified in the paragraph title, the foldout’s number is included in the numeric reference to its item number; for example: <5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number. The foldouts also include other information such as the article number, designation and related data. Note! This manual is not considered as a substitute for a proper training course. The information in the following chapters should be used only after an appropriate course has been completed.

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Repairs

General Description

1.2 Caution Some parts must be moved with precision during any maintenance and repair work, in those cases it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.

1.3 Fitting new bearings and seals 1.3.1 Bearings Do not unwrap new bearings until just before assembly, in order to prevent dust and grit from entering the bearing. ◆ Make sure that all parts of the bearing are free from burr dust, grinding dust and any other contamination. Cast parts must be clean. ◆

◆

Bearing rings, races and roller parts must not under any circumstances be subjected to direct impact. The roller parts must not be subjected to any pressure that is created during the assembly.

Tapered bearings The bearing should be tightened gradually until the recommended pre-tensioning is attained. ◆ The roller parts must be rotated a specified number of turns both before pretensioning and during pre-tensioning. ◆ The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange. ◆ It is important to position the bearings correctly, because this directly affects the service life of the bearing. ◆

Greasing bearings Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as 3HAB 3537-1, should be used. ◆ Grooved ball bearings should be greased on both sides. ◆ Tapered roller bearings and axial needle bearings should be greased when they are split. ◆

Normally the bearings should not be completely filled with grease. However, if there is space on both sides of the bearing, it can be filled completely with grease when it is fitted, as surplus grease will be released from the bearing on start up. ◆ 70-80% of the available volume of the bearing must be filled with grease during operation. ◆ Make sure that the grease is handled and stored correctly, to avoid contamination. ◆

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5

General Description

Repairs

1.3.2 Seals The most common cause of leakage is incorrect mounting. Rotating seals The seal surfaces must be protected during transportation and assembly. ◆ The seals must either be kept in their original packages or be protected well. ◆ The seal surfaces must be inspected before mounting. If the seal is scratched or damaged in such a way that it may cause leakage in the future, it must be replaced. ◆

◆

The seal must also be checked before it is fitted to ensure that: - the seal edge is not damaged (feel the edge with your finger nail), - the correct type of seal is used (has a cut-off edge), - there is no other damage.

◆

Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should 2/3-filled with grease of type 3HAB 3537-1. The rubber coated external diameter must also be greased.

Seals and gears must be fitted on clean workbenches. ◆ Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping. starts. ◆ Always use an assembling tool to fit the seal. Never hammer directly on the seal because this will cause it to leak. ◆ Use a protective sleeve on the sealing edge during assembly, when sliding over threads, key-ways, etc. ◆

Flange seals and static seals ◆

◆

◆ ◆ ◆ ◆

Check the flange surfaces. The surface must be even and have no pores. The evenness can be easily checked using a gauge on the fitted joint (without sealing compound). The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause leakage. The surfaces must be cleaned properly in the manner recommended by ABB ROBOTICS. Distribute the sealing compound evenly over the surface, preferably using a brush. Tighten the screws evenly around the flange joint. Make sure that the joint is not subjected to loading until the sealing compound has attained the hardness specified in the materials specification.

O-rings Check the O-ring grooves. The grooves must be geometrically correct, without pores and free of dust and grime. ◆ Check the O-ring for surface defects and burrs, and check that it has the correct shape, etc. ◆

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Product Manual IRB 140

Repairs

General Description

Make sure the correct O-ring size is used. ◆ Tighten the screws evenly. ◆ Defective O-rings and O-ring grooves must not be used. ◆ If any of the parts fitted are defective, they will cause leakage. Grease the O-ring with 3HAB 3537-1 before fitting it. ◆

1.4 Instructions for tightening screw joints General It is extremely important that all screw joints are tightened using the correct torque. Application Tightening torques must be used, unless otherwise specified in the text, for all screw joints made of metallic materials. The instructions do not apply to screw joints made of soft or brittle materials. For screws with a property class higher than 8.8, the same specifications as for class 8.8. are applicable, unless otherwise stated. Screws treated with Gleitmo All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000. When screwing in new screws without Gleitmo, these should first be lubricated with Molycote 1000 and then tightened to the specified torque. Assembly Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000 should only be used when specified in the text. All screws should be tightened with a torque wrench, if stated.

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General Description

8

Repairs

Product Manual IRB 140

Repairs

Axis 1

2 Axis 1 2.1 Changing the motor of axis 1 See foldout 2 in the list of spare parts. The motor, cable and drive gear constitute one unit. Note! If the manipulator is suspended mounted, it must be dismounted and placed upright standing. To dismantle: Remove cover <57>. ◆ Loosen motor cable connectors, R3.MP1/R3.FB1, inside the console <56>. See Figure 1. ◆

R3.MP1 R3.MP2 R3.FB1 R3.FB2

<2> x4

Figure 1 Cabling for axes 1 and 2.

Cut straps and unscrew braces for screen connections. ◆ Unscrew screws <63>, and pull out the motor cables from the base. ◆ Unscrew screws <52>, holding the motor. ◆ Remove the motor unit. ◆

To assemble: Check that the assembly surfaces are clean and the motor unscratched. ◆ Put O-ring <54> on the motor, apply some grease on the O-ring. ◆ Release the brake, apply 24V DC to terminals 7(+) and 8(-) in the R3.MP1 motor connector. ◆

Install the motor, tighten screws <52> with washers <53> using a torque of approximately 2 Nm. ◆ Mount tool 3HAC 9037-1 “Axis 1-2” at the rear of the motor. ◆

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9

Axis 1

Repairs Adjust the motor in relation to the gear in the gearbox. ◆ Tighten screws <52> using a torque of 11 Nm ±10%. ◆ Connect the cabling. ◆ Calibrate the robot as specified in Calibration Chapter 8. ◆

Tightening torque: The motor attaching screws, item <52>:

11 Nm ±10%

2.2 Changing the gearbox Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and, together with the gearbox for axis 2, forms a complete unit. The gearbox is not normally serviced or adjusted. Note! If the gearbox on any of the axes 1 or 2 needs to be changed, the whole unit must be changed. See foldouts 1 and 2 in the list of spare parts. To dismantle: ◆ ◆ ◆ ◆ ◆

Remove the motors in axes 1 and 2 as in section 2.1 and 3.1. Remove the cabling and serial measuring boards as in Cabling and Serial Measuring board Chapter 6. Dismantle the upper arm as in Dismantling the complete upper arm Chapter 5.5. Dismantle the lower arm as in Dismantling the lower arm Chapter 3.3. Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate <1/2>.

Make sure that the foot is stable. Undo screws <1/16>. ◆ Separate the base from the gear unit. ◆

To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆

10

Place a new gear unit on the table. Put Loctite 574 on the joint base/gear box axis 1. See fold out 1, item <32>. Raise the base. Mount screws <1/16> together with their washer <1/17>. Tighten the screws to a torque of 35 Nm ±10%. Replace the bottom plate <1/2>. Turn the foot. Mount the lower arm as in Dismantling the lower arm Chapter 3.3.

Product Manual IRB 140

Repairs

Axis 1

Mount the upper arm as in Dismantling the complete upper arm Chapter 5.5. ◆ Mount the motors in axes 1 and 2 as in section 2.1 and 3.1. ◆ Mount the cabling as in Cabling and Serial Measuring board Chapter 6. ◆ Calibrate the robot as in Calibration Chapter 8. ◆

Tightening torque: Screwed joint of base/gear unit, item <1/16>:35 Nm ±10%

2.3 Replacing the mechanical stop See foldouts 1 in the list of spare parts. To dismantle: ◆

Remove the cabling as in Cabling and Serial Measuring board Chapter 6.

Note! Lift up the manipulator and place it so that you can work with it in a safe way. Remove the bottom plate <2>, screws <3>. ◆ Undo screws <16>. ◆ Separate the frame/arm system and the base. ◆ Remove mechanical stop <15>. ◆

To assemble: ◆ ◆ ◆ ◆ ◆ ◆

Replace the mechanical stop <15>. Put Loctite 574 on the joint base/gear box axis 1. See fold out 1, item <32>. Mount the frame/arm system and base together with screws <16> and washer <17>. Tighten torque 35 Nm ±10%. Replace the bottom plate <2> using screws <3>. Replace the cabling as in Cabling and Serial Measuring board Chapter 6. Calibrate the robot as specified in Calibration Chapter 8.

Tightening torque: The joint base/arm system, item <16>:

Product Manual IRB 140

35 Nm ±10%

11

Axis 1

12

Repairs

Product Manual IRB 140

Repairs

Axis 2

3 Axis 2 3.1 Changing the motor of axis 2 See foldouts 2 in the list of spare parts. The motor, cable and drive gear constitute one unit. To dismantle: Lock the arm system before dismantling the motor; the brake is located in the motor. Remove cover <57>. ◆ Loosen motor cable connectors, R3.MP2/R3.FB2, inside the console. See Figure 1. ◆ Unscrew screws <63>, and pull out the motor cables from the base. ◆ Unscrew screws <52>, holding the motor. ◆

◆

Remove the motor unit.

Note! The oil will run out of the gear box! Drain the gear box completely, there will be some oil remaining in the bottom of the gear box. To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Check that the assembly surfaces are clean and the motor unscratched. Put O-ring <54> on the motor, apply some grease on the O-ring. Release the brake, apply 24V DC to terminals 7(+) and 8(-) in the R3.MP2 motor connector. Install the motor, tighten screws <52> with washers <53> using a torque of approximately 2 Nm. Mount tool 3HAC 9037-1 “Axis 1-2” at the rear of the motor. Adjust the motor in relation to the gear in the gearbox. Tighten screws <52> using a torque of 11 Nm ±10%. Connect the cabling. Refill the oil through the oil plug placed at the top of the gear box. Volume 1.0 litre (0.25 US gallon) Calibrate the robot as specified in Calibration Chapter 8.

Tightening torque: The motor mounting screws, item <52>:

Product Manual IRB 140

11 Nm ±10%

13

Axis 2

Repairs

3.2 Changing the gearbox Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axis 1, forms a complete unit. The gearbox is not normally serviced or adjusted. Note! If the gearbox of any of the axes 1 or 2 needs to be changed, the whole unit must be changed. See foldout 2 in the list of spare parts. To dismantle: See Chapter 2.2.

3.3 Dismantling the lower arm See foldouts 2 and 3 in the list of spare parts. To dismantle: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Remove the cabling as in Cabling and Serial Measuring board Chapter 6. Dismantle the upper arm as in Dismantling the complete upper arm Chapter 5.5. Dismount motor for axis 3 as in Changing the motor of axis 3 Chapter 4.1. Attach the crane to the lower arm. Unscrew screws <2/52> and remove shaft <2/55>. Remove console <2/56>, screws <2/52>. Knock a screw driver or similar through cover <3/108> and remove it. Unscrew screws <3/16>, holding the lower arm to gear box 2. Remove the lower arm.

To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

14

Lift the lower arm into position. Fix the lower arm to gear box 2 using screws <3/16> and washer <3/17> and tighten them to a torque of 35 Nm ±10%. Mount a new cover <3/108>. Mount console <2/56>, screws <2/52> and washers <2/53>. Tighten to a torque of 11 Nm. Mount shaft <2/55>. Tighten screws to torque of 15.5 Nm. Mount the upper arm as in Dismantling the complete upper arm Chapter 5.5. Mount the motor for axis 3 as in Changing the motor of axis 3 Chapter 4.1. Mount back the cabling as in Cabling and Serial Measuring board Chapter 6.

Product Manual IRB 140

Repairs ◆

Axis 2 Calibrate the robot as in Calibration Chapter 8.

Tightening torque: Screwed joint of lower arm/gear box, item <3/16>: 35 Nm ±10% Screws for console, item <2/52>: 11 Nm Screws for support bearing, item <2/52>: 15.5 Nm

3.4 Changing the support bearing in the lower arm See foldouts 2 and 3 in the list of spare parts. To dismantle: Remove the lower arm as in Dismantling the lower arm Chapter 3.3. ◆ Knock out bearing <3/107>. ◆

To assemble: Put a support under the lower arm. ◆ Gently knock a new bearing in position, see Figure 2, in the lower arm. ◆

Note! Do not knock on the inner ring!

Under arm and bearing even level Support

Figure 2 Position of the bearing in the lower arm after mounting.

Mount the lower arm as in Dismantling the lower arm Chapter 3.3. ◆ Calibrate the robot as in Calibration Chapter 8. ◆

Tightening torque: Screwed joint of lower arm/gear box, item <3/16>: 35 Nm ±10% Screws for console, item <2/52>: 11 Nm ±10% Screws for support bearing, item <2/52>: 15.5 Nm ±10% Product Manual IRB 140

15

Axis 2

16

Repairs

Product Manual IRB 140

Repairs

Axis 3

4 Axis 3 4.1 Changing the motor of axis 3 See foldouts 3 in the list of spare parts. The motor and the belt pulley constitute one unit. To dismantle: Remove cover <101 (102)>. ◆ Loosen the cabling inside the lower arm. See Figure 3. ◆

Air

Power axes 4, 5, 6

Straps Signal axis 3 Signal axes 4, 5, 6

B

B R3.MP3 R3.FB3

Customer signal Section B - B

Figure 3 Cable layout in the lower arm.

Disconnect contacts R3.MP3/R3.FB3 for the motor and also R3H1/H2 if option “Safety lamp” is fitted. ◆ Loosen the two screws <111> that hold the shield + motor and remove the belt shield <106>. ◆ Unscrew the other two motor screws <111> and remove the belt <105>. ◆ Take out the motor. ◆

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17

Axis 3

Repairs To assemble: ◆ ◆ ◆ ◆ ◆ ◆

Check that the assembly surfaces are clean and the motor unscratched. Place the motor in the lower arm. Mount the belt <105>. Mount two of the screws <111> with washers <112> that hold the motor. Tighten the two motor screws <111> just enough so that you can move the motor. Move the motor until you have a good belt tension, see section 4.3.

Warning! Do NOT adjust the belt by loosen the screws for the intermediate wheel. Tighten motor screws <111> with washers <112> to a torque of 4.1 Nm ±10%. ◆ Mount the shield <106> with the two other motor screws, tighten motor screws <111> with washers <112> to a torque of 4.1 Nm ±10%. ◆ Fix the cabling, according to Figure 3. ◆ Calibrate the robot as specified in Calibration Chapter 8. ◆

Tightening torque: The motor’s mounting screws, item <111>:4.1 Nm ±10%

4.2 Gear box axis 3 Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and fitted inside the upper part of the lower arm. The gearbox is not serviced. To change the gear box the complete lower arm must be replaced, see Dismantling the lower arm Chapter 3.3.

4.3 Changing the drive belt See foldout 3 in the list of spare parts. To dismantle: Remove cover <101 (102)>. ◆ Loosen the cabling inside the lower arm. See Figure 3. ◆ Loosen screws <111> that hold the shield and remove it. ◆ Loosen the other two motor screws <111> and remove the belt <105>. ◆

To assemble: Replace the drive belt. ◆ Tighten the two motor screws <111> with washers <112>, that hold the motor, just enough so that you can move the motor. ◆

◆

18

Move the motor until you have a good belt tension. See Figure 4. Product Manual IRB 140

Repairs

Axis 3

Warning! Do NOT adjust the belt by loosen the screws for the intermediate wheel. Tighten motor screws <111> with washers <112> to a torque of 4.1 Nm ±10%. ◆ Mount the belt shield <106> with the other two motor screws <111>. ◆

F= 35-60 N F

F

Figure 4 Belt tension.

◆

Tighten screws <111> to a torque of 4.1 Nm ±10%.

Fix the cabling, according to Figure 3. ◆ Calibrate the robot as specified in Calibration Chapter 8. ◆

Tightening torque: The motor’s mounting screws, item <111>:4.1 Nm ±10%

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Axis 3

20

Repairs

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Repairs

Upper arm, axes 4-6

5 Upper arm, axes 4-6 5.1 Changing the motors See foldout 4 and 5 in the list of spare parts. The motor and the drive gear constitute one unit. 5.1.1 Motor axis 4 To dismantle: Remove motors for axes 5-6 as in 5.1.2. ◆ Place the upper arm with the wrist pointing downwards. So that the oil remains inside the gear box. ◆ Use a long Allen key and unscrew screws <4/111>. ◆

◆

Lift out the motor.

To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Check that the assembly surfaces are clean and the motor unscratched. Put O-ring <4/161> on the motor. Apply some grease on the O-ring. Release the brake, apply 24V DC to terminals 7(+) and 8(-) in the R3.MP4 motor connector. Install the motor, tighten screws <4/111> with washers <4/112> to a torque of approximately 2 Nm. Fit tool art. no. 3HAC 9037-1 “Axis 4” on the end of the motor shaft. Adjust the position of the motor in relation to the gear in the gear box. Make sure there is a small clearance. Tighten screws <4/111> to a torque of 6 Nm ±10%. Remount motors for axes 5-6 as in 5.1.2. Calibrate the robot as in Calibration Chapter 8.

Tightening torque: The motor’s mounting screws, item <4/111>:6 Nm ±10% Tool: Crank tool for checking the play: (the tools are marked with axis no.)

Product Manual IRB 140

3HAC 9037-1 “Axis 4” 3HAC 9037-1 “Axis 5” 3HAC 9037-1 “Axis 6”

21

Upper arm, axes 4-6

Repairs

5.1.2 Motor axes 5 and 6 See foldout 3, 4 and 5 in the list of spare parts. The motor and the drive gear constitute one unit. To dismantle: Remove cover <4/174> at the rear of the upper arm. ◆ Remove cover <3/101 (102)>. ◆

Insert a thin long blunt punch and gently knock the cover <4/108> out. ◆ Disconnect contacts R3.MP4, 5, 6 and R3.FB4, 5, 6, also remove customer contact R2.CS + air hose, see Figure 5. ◆

R2.CS Air

R3.FB4 R3.FB5

R3.MP5

R3.MP4

R3.FB6

R3.MP6

Figure 5 Contacts at the rear of the upper arm.

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Remove shield <5/177>. Cut the straps holding the cables in the lower arm. Pull out the cables from the upper arm. Remove cable holder <4/173>. Loosen screws <4/111 and 163> for the motors axes 5 and 6. Unscrew the screws in the coupling <4/172>. Move the two screws to the other two threaded holes in the coupling and press the two parts in the coupling apart. Remove the coupling and pull out the pulley <4/171> and drive belt <4/169> for axis 6. Unscrew screws <4/165>. Pull out the pulley <4/170> and drive belt <4/169> for axis 5.

Note! The pulley has a precision sliding fit.

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Product Manual IRB 140

Repairs ◆

Upper arm, axes 4-6 Unscrew screws <4/163> and pull out the motor console <4/164> with motors.

Note! the position of the motors, see Figure 6. Do not mix up the motors. Axis 5 motor

Cable outlet Cable outlet

Axis 6 motor

Cable outlet

Figure 6 Position of motors axis 5 and 6.

◆

Remove the motors.

To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Mount the motors in console <4/164>, do not tighten the screws. Insert the console with the motors in the upper arm housing. Mount console screws <4/163> with washers <4/112> tighten to a torque of 4.1 Nm ±10%. Mount pulley <4/170> and drive belt <4/169> for axis 5 with screws <4/165> and washers <4/166>, tighten to a torque of 4.1 Nm ±10%. Tighten the motor screws <4/163> with washers <4/112> just enough so that you can move the motor. Press the motor until you have a good belt tension. See Figure 4. Tighten screws <4/163> to a torque of 4.1 Nm ±10%. Mount pulley <4/171> and drive belt <4/169> for axis 6 with coupling <4/172>. Tighten the screws in the coupling to a torque of 3 Nm ±10%. Tighten the motor screws <4/111> with washers <4/112> just enough so that you can move the motor. Press the motor until you have a good belt tension. See Figure 4. Tighten screws <4/111> to a torque of 4.1 Nm ±10%. Mount belt shield <4/173> with screws <4/163> and washers <4/112>. Connect the cabling, see Contacts at the rear of the upper arm. Chapter Figure 12.

Product Manual IRB 140

23

Upper arm, axes 4-6

Repairs

Fix the cabling in the lower arm according to Cable layout in the lower arm. Chapter Figure 15. ◆ Mount cover <3/101 (102)>. ◆ Mount cover <4/108> and cover <4/174> with sealing <4/175>. ◆ Calibrate the robot as in Calibration Chapter 8. Tightening torque: The motor’s fixing screws, item <4/111/163>: 4.1 Nm ±10% Screws for motor console, item <4/163>: 4.1 Nm ±10% Screws for drive belt, item <4/165>: 4.1 Nm ±10% Screws for coupling <4/172>: 3 Nm ±10% ◆

5.2 Dismantling the wrist The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears. It is of such a complex design that it is not normally serviced on-site, but should be sent to ABB Flexible Automation to be serviced. ABB ROBOTICS recommends its customers to carry out only the following servicing and repair work on the wrist. - Change the oil the wrist according to the table in the maintenance chapter. See foldouts 4 in the list of spare parts. To dismantle: Remove the oil plugs on the wrist and drain it as described in chapter 14, Maintenance. ◆ Undo screws <153> and remove the wrist. ◆

To assemble: ◆ ◆ ◆ ◆ ◆ ◆

24

Mount O-ring sealing plate <152>, apply some grease on the O-ring. Take the upper arm to a vertical position, wrist side pointing upwards. Mount the wrist. Do not tighten the screws. Release the brakes on axes 5 and 6, apply 24V DC to terminals 7(+) and 8 in the R3.MP5(6) connector at the rear of the upper arm. Mount tool 3HAC 9037-1 “Axis 5 and “Axis 6” at the rear of each motor. Push the wrist, as shown in Figure 7, to locate the smallest play in the same way as for adjusting play when changing motors for axes 1 and 2.

Product Manual IRB 140

Repairs

Upper arm, axes 4-6

Upper arm seen from the front

Gears on drive shaft unit axes 5 and 6

Gears on the wrist

Figure 7 Adjusting the play on the wrist.

Tigthten screws <153> with washers <154> to a torque of 28 Nm. ◆ Check the play by moving axes 5 and 6 by hand. ◆ Fill with oil according to the Maintenance chapter. ◆

◆

Calibrate the robot as in Calibration Chapter 8.

Tightening torque: Screwed joint of wrist/tubular shaft, item <153>:28 Nm ±10%

5.3 Exchanging the upper housing, with motor units See foldouts 3 and 4 in the list of spare parts. To dismantle: Dismantle the wrist as in section 5.2. ◆ Remove the cabling from the upper arm as in Changing the cabling for axes 3, 4, 5 and 6 Chapter 6.3. ◆ Remove the upper arm as in section 5.5. ◆

To assemble: Mount the upper arm as in 5.5. ◆ Fit the cabling as in Changing the cabling for axes 3, 4, 5 and 6 Chapter 6.3. ◆ Mount the wrist as in section 5.2. ◆

Tightening torque: Screwed joint of wrist/tubular shaft, item <4/153>: 28 Nm ±10% Screw joint upper arm/lower arm, item <4/157>: 35 Nm ±10%

Product Manual IRB 140

25

Upper arm, axes 4-6

Repairs

5.4 Changing the driving belt on axes 5 and 6 See foldout 4 in the list of spare parts. To dismantle: Remove cover <174>. ◆ Disconnect the contacts at the rear of the upper arm, see Figure 5. ◆

◆ ◆ ◆ ◆ ◆

Remove belt shield <173>. Loosen the screws <111> for motor axis 6. Unscrew screws in coupling <172>. Move the two screws to the other two threaded holes in the coupling and press the two parts in the coupling apart. Remove the coupling and pull out the pulley <171> and drive belt <169> for axis 6.

Note! If the belt for axis 5 is to be changed continue as below. Loosen screws <163> for motor axis 5. ◆ Unscrew screws <165>. ◆ Pull out the pulley <170> and drive belt <169> for axis 5. ◆

Note! The pulley has a precision sliding fit. To assemble: ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Mount pulley <170> and drive belt <169> for axis 5. Tighten the motor screws <163> just enough so that you can move the motor. Push the motor until you have a good belt tension. See Figure 4. Tighten screws <163> to a torque of 4.1 Nm ±10%. Mount pulley <171> and drive belt <169> for axis 6. Tighten the motor screws <111> just enough so that you can move the motor. Push the motor until you have a good belt tension. See Figure 4. Tighten screws <111> to a torque of 4.1 Nm ±10%. Mount belt shield <173>. Connect the cabling. Mount cover <174> with sealing <175> with screws <8> and <12>. Calibrate the robot as in Calibration Chapter 8.

Tightening torque: The motor’s fixing screws, item <163, 111>:4.1 Nm ±10% Screws for drive belt, axis 5, item <165>: 4.1 Nm ±10% Screws in coupling <172>, axis 6: 3 Nm ±10%

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Product Manual IRB 140

Repairs

Upper arm, axes 4-6

5.5 Dismantling the complete upper arm See foldout 4 and 5 in the list of spare parts. To dismantle: Attach a crane to the upper arm. Remove the cabling to the upper arm as in Changing the cabling for axes 3, 4, 5 and 6 Chapter 6.3. ◆ Attach a hoist to the upper arm. ◆ Unscrew screws <4/157> fixing the upper arm to the lower arm. ◆ Remove the upper arm. ◆

To assemble: ◆

Place the upper arm in position.

Tighten screws <4/157> with washers <4/158> to a torque of 35 Nm ±10%. ◆ Fit the cabling as in Changing the cabling for axes 3, 4, 5 and 6 Chapter 6.3. ◆ Mount cover <4/108>. ◆

Tightening torque: Screw joint lower arm/upper arm, item <4/157>:35 Nm ±10%

5.6 Measuring the play on wrist 5.6.1 Axis 5 Axis 4 must be turned 90o. Load the measurement arm with 40 N in the specified direction according to “Measure 1”, unload the arm and read value 1*. Then load the measurement arm with 40 N in the specified direction, according to “Measure 2”, unload the arm and read value 2*. The difference between the two values is the maximum accepted play on axis 5. The maximum accepted play measured according to Figure 8 is 0.18 mm. This corresponds to 4.1 arc. minutes.

Product Manual IRB 140

27

Upper arm, axes 4-6

Repairs

View from above “Measure 2”

“Measure 1” 40 N

40 N

* Play = value 1 - value 2 Figure 8 Measuring the play on axis 5.

5.6.2 Axis 6 Axis 4 must be turned 90o (to eliminate the influence of axis 5). Load the measurement arm with 40 N in the specified direction according to “Measure 1”, unload the arm and read value 1*. Then load the measurement arm with 40 N in the specified direction, according to “Measure 2”, unload the arm and read value 2*. The difference between the two values is the maximum accepted play on axis 6. The maximum accepted play measured according to Figure 9 is 0.30 mm. This corresponds to 10.3 arc. minutes. Front view “Measure 1”

“Measure 2”

40 N

40 N

* Play = value 1 - value 2 Figure 9 Measuring the play on axis 6.

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Cabling and Serial Measuring board

6 Cabling and Serial Measuring board 6.1 Changing the serial measuring board See foldout 1 in the list of spare parts. To dismantle: Remove cover <13(14)> from the base. ◆ Unscrew screws <8> holding the serial measurement board. ◆ Lift out the serial measurement board <5>. ◆ Disconnect the contacts R2.SMB, R2.FB1-3, R2.FB 4-6 and R2.G from the board, see Figure 10. ◆

R2.FB 4-6

R2.SMB R2.FB 1-3

R2.G

Figure 10 Position of contacts on serial measurement board.

To assemble: ◆

Assemble in the reverse order.

6.2 Cabling axes 1 and 2 The cables from motors axes 1-2 are a part of the motor and can therefore not be changed without changing the complete motor.

6.3 Changing the cabling for axes 3, 4, 5 and 6 See foldouts 1-4 in the list of spare parts. The cabling from the base up to the upper arm consists of one complete unit except for the cabling from the motors for axes 1 and 2. Product Manual IRB 140

29

Cabling and Serial Measuring board

Repairs

To dismantle: Remove the serial measurement board as in 6.1 ◆ Disconnect the contacts. See Figure 11. ◆

R1.CS R1.MP 1-3 R1.MP 4-6 Air hose

Figure 11 Cabling layout for base cover.

◆ ◆ ◆ ◆ ◆ ◆

Loosen the cable holder <1/9> in the base, screws <1/3>. Remove the holder from the cables, screws <1/12>. Remove cover <4/174> at the rear of the upper arm. Remove cover <3/101(102)>. Insert a long blunt punch and gently knock out cover <4/108>. Disconnect contacts R3.MP4, 5, 6 and R3.FB4, 5, 6, also remove customer contact R2.CS + air hose, see Figure 12. R2.CS Air

R3.FB4 R3.FB5

R3.MP5

R3.MP4

R3.FB6

R3.MP6

Figure 12 Contacts at the rear of the upper arm.

◆

Remove shield <5/177>.

Cut the straps holding the cables in the lower arm. ◆ Disconnect contacts R3.MP3 and R3.FB3, see Figure 3. ◆ Pull out the cables from the upper arm. ◆

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Product Manual IRB 140

Repairs

Cabling and Serial Measuring board

Remove cover <2/57> at the top of the console <2/56>. ◆ Loosen the cable holders and disconnect contacts for axes 1 and 2, see Figure 13. ◆

Nuts (x2) R3.FB1 R3.FB2 R3.MP1 R3.MP2

Screws (x2) Figure 13 Cables inside the console.

Pull up the cabling from the base through the console. ◆ Pull out the cabling from the lower arm. ◆

To assemble: ◆

Assemble in the reverse order.

Note! Below are some diagrams showing how cables are routed in the manipulator. Signal

Power axes 4-6

Signal

Air

Customer signal

Power axes 1-3

Figure 14 Cable holder in the base.

Product Manual IRB 140

31

Cabling and Serial Measuring board

Repairs

Power axes 4, 5, 6

Air

Signal axis 3

B

B

Signal axes 4, 5, 6 Customer signal Section B - B

Figure 15 Cable layout in the lower arm.

Customer signal Power Signal Air

See also foldout 5

Figure 16 Cable holder in the upper arm.

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Product Manual IRB 140

Repairs

Motor Units

7 Motor Units General Each axis of the manipulator has its own motor unit, comprising: - a synchronous motor - a brake (built into the motor) - a feedback device. There are a total of six motors mounted in the manipulator. The power and signal cables are run to respective motors from the cable connector points on the manipulator. The cables are connected to the motor units. The drive shaft of the electric motor forms a part of the gearbox on the manipulator axis. A brake, operated electromagnetically, is mounted on the front of the motor shaft and a pinion is mounted on its drive end. The brake releases when power is supplied to the electromagnets. Note! there is a feedback device mounted on each motor unit. The device is installed by the supplier of the motor and should never be removed from the motor. The motor never needs to be commutated. The commutation value of the motors is: 1.570800. The motor, resolver and brakes are regarded as one complete unit.

Product Manual IRB 140

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Motor Units

34

Repairs

Product Manual IRB 140

Repairs 8 Calibration 8.1 General The robot measurement system consists of one feedback unit for each axis and a measurement board that continuously keeps track of the current robot position. The measurement board memory has a battery backup. If any of the resolver values have been changed, the measurement system must be carefully calibrated (as described in Chapter 8.4, Fine calibration). This can happen when: - parts affecting the calibration position have been replaced on the robot. The system needs to be roughly calibrated (as described in Chapter 8.5, Updating revolution counter) if the contents of the revolution counter memory are lost. This may happen when: - the battery is discharged. - a resolver error occurs. - the signal between a resolver and measurement board is interrupted. - a robot axis has been moved with the control system disconnected.

8.2 Checking the calibration position Before any programming of the robot system can begin, a check of the calibration position must be made. There are two ways to check the calibration position. A. Using the diskette, Controller Parameters: 1. Run the program \ SERVICE \ CALIBRAT \ CAL 140 on the diskette, follow the instructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. 2. Check that the calibration marks for each axis are at the same level (see Figure 24) If they are not, the setting of the revolution counters must be repeated. 3. Check resolver offset values in system parameters. B. Using the Jogging window on the teach pendant: 1. Open the Jogging window and choose running axis-by-axis. Using the joystick, move the robot so that the read-out on the teach pendant is equal to zero. 2. Finish by making checks as described above in A, point 2 and 3.

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Repairs 8.3 Fine calibration procedure on the teach pendant 1. Press the Misc. window key (see Figure 17).

7 4 1 1 2

8 5 2 0

9 6 3

P2

P1

P3

Figure 17 The Misc. window key from which the Service window can be selected

2. Select Service in the dialog box shown on the display. 3. Press Enter

.

4. Select View: Calibration. The window shown in Figure 18 appears. File

Edit

View

Calib

Service Calibration Unit

Status 1(4)

IRB

Not Calibrated

Figure 18 The window shows whether or not the robot system units are calibrated.

The calibration status can be any of the following: - Synchronised All axes are calibrated and their positions are known. The unit is ready for use. - Revolution Counter not updated All axes are fine-calibrated but one (or more) of the axes has a counter that is NOT updated. This axis, or these axes, must therefore be updated as described in Chapter 8.5, Updating revolution counter. - Not calibrated One (or more) of the axes have NOT been fine-calibrated. This axis, or these axes, must therefore be fine-calibrated as described in Chapter 8.4, Fine calibration. 5. If there is more than one unit, select the desired unit in the window in Figure 18. 36

Product Manual IRB 140

Repairs Choose Calib: Fine Calibrate and the window shown in Figure 19 will appear.

Warning! Fine Calibration Make sure that the robot is placed in its calibration position, according to the manual.

Cancel

OK

Figure 19 Place the manipulator in its calibration position.

6. Press OK. Figure 23 will appear.

Fine Calibrate! IRB To calibrate, include axes and press OK. Axis X X

Status

1 2 3 4 5 6

X X

Excl

Not Fine Calibrated Not Fine Calibrated Fine Calibrated Fine Calibrated Not Fine Calibrated Not Fine Calibrated

All

Cancel

1(6)

OK

Figure 20 The dialog box used to calibrate the manipulator.

7. If all the axes are to be calibrated, press the function key All to select all axes. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with a “x”). 8. Confirm by pressing OK. The window shown in Figure 21 appears.

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Repairs

Fine calibrate!

The calibration for all marked axes will be changed. It cannot be undone! OK to continue?

Cancel

OK

Figure 21 The dialog box used to start calibration.

9. Start calibration by pressing OK. An alert box is displayed during calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed.

8.4 Fine calibration The axes must be adjusted in increasing sequence, i.e., 1 - 2 - 3 - 4 - 5 - 6. Move the robot to the calibration position, corresponding to the calibration marks, as shown in Figure 24. 8.4.1 Axis 1 1. Remove the cover plate on the reference surface on the base of the manipulator. Clean the surface with ethanol and deburr it. 2. Attach the calibration tool 3HAC 0181-1 to the flat surface. See Figure 22. 3. Turn the operating mode selector to MANUAL MODE AT REDUCED SPEED. 4. Release the brakes and turn axis 1 by hand until the pin, located under the axis 1 gear box, fits in the measuring slot on tool 3HAC 0181-1. Be very careful when releasing the brakes. The axes become activated very quickly and may cause damage or personnel injury. 5. Update axis 1 only as described in section 8.3. 6. Remove the calibration tool for axis 1.

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Product Manual IRB 140

Repairs

Tool 3HAC 0181-1

Pin

Figure 22 Calibration tool for axis 1.

8.4.2 Axes 2 - 6 1. Fit the tool 6808 0011-GM on the reference surface on the manipulator base. 2. The readings given below are valid for level meter type B25 (1 unit = 0.025mm/m). Note! The reading 0001 on the display is equal to 1 unit. 3. Calibrate the sensors against each other, using a reference plane on tool 6808 0011-GM, in the same direction. The sensors must be calibrated every time they are used for a new direction. See Figure 23. Level meter B25

Level sensors

Reference plane 6808 0011-GM

,0000 0000

Y Calibrating sensors for axes 2, 3 and 5 X

Y Calibrating sensors for axes 4 and 6 X

Figure 23 Calibrating the sensors.

4. Clean the reference surface and fit the tool 6808 0011-LP on the lower arm. Adjust the angle of the tool with the help of the sensors before starting calibration.

Product Manual IRB 140

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Repairs 5. Fit the tool 6808 0011-GU, adapter 6896 134-GZ, and pin 2111 2021-399, on the tool flange. 6. Turn the tool clockwise against the guiding pin at the same time as the screws are tightened. 7. Position the sensors as shown in Figure 25. 8. Jog axis 2 to the correct position so that the level meter shows 0±8 units. 9. Update only axis 2, as described in section 8.3. Remove the sensor. 10. Run the program \SERVICE\CALIBRAT\ CAL140 on the system parameter disk and select Calib: CAL3. The robot will now move to the position for calibration of axis 3. 11. Put the sensors on the shelf and jog the robot to the calibration position, 0±8 units. See Figure 25. 12. Update only axis 3, as described in section 8.3. Remove the sensor. 13. Select CAL4A and the robot will now move to the position for calibration of axis 4. 14. Calibrate the sensors for the Y-direction. See Figure 23. 15. Jog axis 4 to the correct position as indicated by the level meter, 0 ±16 units. 16. Update only axis 4, as described in section 8.3. Remove the sensor. 17. Select CAL4B. 18. The robot will now be standing in the correct position for fine calibration of axis 4. 19. Update only axis 4, as described in section 8.3. 20. Select CAL5 and the robot will now move to the position for calibration of axis 5. 21. Calibrate the sensors for the X-direction. See Figure 23. 22. Put the sensors on the shelf and jog axis 5 to the correct position, 0 ±16 units. See Figure 25. 23. Update only axis 5, as described above. 24. Calibrate the sensors for the Y-direction. See Figure 23. 25. Run axis 6 to the correct position 0±16 units. See Figure 25. 26. Update only axis 6, as described in section 8.3. 27. Run the calibration program twice, check the calibration positions of axes 2, 5, and 6. The acceptable calibration accuracy is shown in the table below. If axes 5 and 6 are within the tolerances, then axes 3 and 4 do not need to be checked. Calibration accuracy: Axis

Accuracy

2-3

±16 units

4-6

±32 units

Note! The axes must not be changed during measurement. 28. Save the system parameters on a floppy disk. 40

Product Manual IRB 140

Repairs

Axis 2

Label

Axis 1

Punch tool 3HAC 8481-1 Axis 4

Reference surfaces to be parallel Axis 3

Axis 5

Axis 6

Figure 24 Calibration marking.

29. Change the values on the label located on the console, see Figure 24. 30. Remove the tools from the manipulator. 31. The calibration position for axis 4 is marked using punch mark tool, 3HAC 8481-1. Remove the old mark using a file. Product Manual IRB 140

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Repairs

Axes 2 Upper arm seen from above Axis 3

Axis 4 Reference

Axis 5

Axes 2, 3 and 5

Axes 4 and 6

Axis 6

Figure 25 Directions for calibration, reference surface.

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8.5 Updating revolution counter When starting up a new robot, you may receive a message telling you that the manipulator is not synchronised. The message appears in the form of an error code on the teach pendant. If you receive such a message, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator. See Figure 24. Examples of when the revolution counter must be updated: - when the battery unit is discharged - when there has been a resolver error - when the signal between the resolver and the measuring system board has been interrupted - when one of the manipulator axes has been manually moved without the controller being connected. Note! The accumulator unit will be fully recharged when the mains supply has been on for 36 h without any power interruptions. If the resolver values must be calibrated, this is described in section 8.4. WARNING Working in the robot work cell is dangerous. Press the enabling device on the teach pendant and, using the joystick, move the robot manually so that the calibration marks lie within the tolerance zone (see Figure 24). Note that axes 4 and 6 do not have any mechanical stop and can thus be calibrated at the wrong faceplate revolution. Do not operate axes 4 and 6 manually before the robot has been calibrated. When all axes have been positioned as above, the values of the revolution counter can be stored by entering the following commands on the teach pendant: 1. Press the Misc. window key (see Figure 26).

1 2

P1

7

8

9

4 1

5 2 0

6 3

P2 P3

Figure 26 The Misc. window key from which the Service window can be selected

Product Manual IRB 140

43

Repairs 2. Select Service in the dialog box shown on the display. 3. Press Enter

.

4. Then, choose View: Calibration. The window shown in Figure 27 appears. File

Edit

View

Calib

Service Calibration Mech Unit

Status 1(4)

IRB

Rev Counter Not Updated

Figure 27 This window shows whether or not the robot system units are calibrated.

5. Select the desired unit in the window, as shown in Figure 27. Choose Calib: Rev. Counter Update. The window in Figure 28 appears.

Rev. Counter Update! IRB To calibrate, include axes and press OK. Axis

Status 1(6)

X X

X X

1 2 3 4 5 6

Excl

Rev. Rev. Rev. Rev. Rev. Rev.

All

Counter Counter Counter Counter Counter Counter

Not updated Not updated updated updated Not updated Not updated

Cancel

OK

Figure 28 The dialog box used to select axes for which the revolution counter is to be updated.

6. If all the axes are to be updated, press the function key All to select all axes. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with a “x”).

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Product Manual IRB 140

Repairs 7. Confirm by pressing OK. A window like the one in Figure 29 appears.

Rev. Counter Update!

The Rev. Counter for all marked axes will be updated. It cannot be undone. OK to continue?

Cancel

OK

Figure 29 The dialog box used to start updating the revolution counter.

8. Start the update by pressing OK.

If a revolution counter is incorrectly updated, it will cause incorrect positioning. Therefore, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone. 9. Check the calibration as described in Chapter 8.2, Checking the calibration position. 10. Save the system parameters on a floppy disk.

Product Manual IRB 140

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Repairs

46

Product Manual IRB 140

Spare Parts List CONTENTS Page 1 Spare Parts Manipulator................................................................................... 2 1.1 Manipulator complete ................................................................................ 2

Product Manual IRB 140

1

Spare Parts List 1 Spare Parts Manipulator Item number refers to item number on the foldouts.

1.1 Manipulator complete Itm

2

Qty

Name

Art. no

Rem

1

1

3HAC 10470-1

Base spare

2

1

3HAC 8999-1

Bottom plate

3

26

9ADA 629-44

Torx pan head roll. screw

4

1

3HAC 6599-1

Gasket bottomplate

5

1

3HAC 9522-1

Serial meas. board ass.

6

1

4944 026-4

Battery pack

7,2V 4Ah NiCd

7

2

2166 2055-6

Cable straps, outdoors

7,6x368

8

28

9ADA 618-46

Torx pan head screw

M5x20

9

1

3HAC 9030-1

Cable bracket

10

1

3HAC 9415-1

Clamp

11

1

3HAC 6755-1

Cable holder

12

4

9ADA 618-50

Torx pan head screw

M5x40

13

1

3HAC 10476-1

Control cable spare

L=3m

14

1

3HAC 10477-1

Control cable spare

L=7m

15

1

3HAC 7527-1

Damper ax. 1

16

20

3HAB 3402-52

Hex socket head cap screw

17

2

3HAC 7950-1

Washer

18

2

3HAC 9860-1

Protecting plate

19

1

3HAC 8466-1

Protective earth cable

20

2

3HAC 9063-1

Hose clip

21

1

SK 615 503-2

Membrane

22

1

SK 616 013-F

Bracket

23

1

1SFA 616100R1006

Actuator black

M5x12

M10x35 8.8 Gleitmo 610

D=10

CBK

Product Manual IRB 140

Spare Parts List

24

1

3HAC 7870-1

Gasket base-cover

25

9

9ADA 290-1

Hexagon nut with flange

M5

26

1

2529 1920-2

Plug

R 1/8"

27

2

2522 2101-8

Protective hood

D=11,4-13

28

1

3HAC 8806-1

Clamp

29

1

3HAC 7370-1

Cable harness IRB 140

30

1

3HAC 2589-1

Instruction plate

Battery replacement

31

10

2166 2055-3

Cable straps, outdoors

4,8x208

32

20 ml

1234 0011-116

Flange sealing

Lotctite 574

50

1

3HAC 10467-1

Gearbox axis 1-2, spare

Item 67 incl.

51

1

3HAC 10469-1

Motor with pinion spare

52

24

3HAB 3409-25

Hex socket head cap screw

M6x20 12.9 Gleitmo 610

53

18

9ADA 312-6

Plain washer

6,4x12x1,6

54

2

2152 2012-426

O-ring

74,5x3

55

1

3HAC 6788-1

Bearing hub

56

1

3HAC 10478-1

Console spare

57

1

3HAC 10472-1

Cover consol spare

58

1

3HAC 7868-1

Gasket console-cover

59

1

3HAC 5894-1

Cable bracket

T=1,5

60

1

3HAC 6965-1

Sealing ring

150x189x8,5

61

3

3HAC 3785-6

Parallel pin

D=6 m6 L=16

62

2

3HAB 3732-18

Sealing ring (V-ring)

63

11

9ADA 618-55

Torx pan head screw

M6x12

64

2

2166 2018-2

Clamp

D=11

65

1

3HAC 6764-1

Connector bracket

66

25

2166 2055-1

Cable straps, outdoors

67

3000 ml

1171 2016-604

Lubricating oil

100

1

3HAC 10468-1

Lower arm (axis 3), spare

Item 67, 107 and 108 incl.

101

1

3HAC 10471-1

Cover, without lamp unit

Item 103 incl.

102

1

3HAC 10474-1

Cover, with lamp unit

Item 103 incl.

Product Manual IRB 140

Item 58 incl.

2,5x101

3

Spare Parts List

4

103

1

3HAC 7869-1

Gasket lower-arm cover

104

1

3HAC 7866-1

Rot. ac motor incl pinion

105

1

3HAC 6793-1

Timing belt

106

1

3HAC 6762-1

Belt shield

107

1

3HAB 3643-17

Groove ball bearing

80x100x10

108

2

3HAA 2166-13

VK-Cover

D=100 B=10

109

1

3HAC 7880-1

Damper ax. 2

110

1

3HAA 2356-14

Washer SRKB

6,4x18x1,6

111

4

3HAB 3402-15

Hex socket head cap screw

M5x20 8.8 Gleitmo 610

112

12

9ADA 312-5

Plain washer

5,3x10x1

113

1

3HAC 9258-1

Indicator lamp

150

1

3HAC 10466-1

Upper arm compl. with wrist

Motors incl.

151

1

3HAC 10475-1

Wrist spare

Item 155, 181 and 182 incl.

152

1

3HAC 7191-1

O-ring sealingplate

153

3

3HAB 3409-37

Hex socket head cap screw

M8x25 12.9 Gleitmo 610

154

3

9ADA 312-7

Plain washer

8,4x16x1,6

155

3

2529 1920-2

Plug

R 1/8"

156

1

3HAC 10479-1

Axis 4 complete spare

Item 111, 112, 180, 159, 161, 160 and 182 incl.

157

6

3HAB 3409-39

Hex socket head cap screw

M8x35 12.9 Gleitmo 610

158

6

9ADA 334-7

Spring washer,conical

8,4x18x2

159

1

3HAB 3732-13

Sealing ring (V-ring)

99x10,5

160

1

3HAC 7842-1

Rot. ac motor with pinion

161

1

3HAB 3772-24

O-ring

162

2

3HAC 7841-1

Rot. ac motor with pinion

163

4

3HAB 3402-18

Hex socket head cap screw

164

1

3HAC 6773-1

Motor Console ax.5-6

165

5

9ADA 183-13

Hex socket head cap screw

M5x12

166

3

3HAA 2356-15

Washer SRKB

5,3x15x1,2

167

1

3HAC 7367-1

Cable holder

29x3

M5x35 8.8 Gleitmo 610

Product Manual IRB 140

Spare Parts List 168

1

3HAC 8572-1

Clamp

169

2

3HAC 6779-1

Timing belt

170

1

3HAC 6777-1

Timing Belt Pulley Z2/5

171

1

3HAC 6778-1

Timing Belt Pulley Z2/6

172

1

3HAC 7939-1

Clamping unit

173

1

3HAC 7391-1

Belt shield

174

1

3HAC 10473-1

Cover armhousing spare

175

1

3HAC 7867-1

Gasket upper arm cover

176

1

3HAC 7881-1

Damper ax. 3

177

1

3HAC 6761-1

Cable guide

178

1

3HAC 7561-3

Dustcap f receptacles 12p

179

2

2125 2052-178

Distance bolt

M5X55

180

1

3HAC 6598-1

Hose nipple

G 1/4"

181

1

3HAB 8964-1

Damper Axis 5

182

550 ml

3HAC 0860-1

Lubricating oil

Product Manual IRB 140

Item 175 incl.

Optimol Optigear BM 100

5

1

15

8

27

18

32

13

3

14

20

31

19

R1/4

21

22

23

28

3

Inside of cover

4

7

5

16

35 Nm

17

24

6

8

12

11

9

26

29

31

3

10

Inside of base 2

3

30

25

Base complete

Foldout 1

31 51

62

56

8

58

57

52

11 Nm

53

65

25

32

62

52

55

31 11 Nm

15,5 Nm

52

53

11 Nm

54

52

53

52

11 Nm

51

53

54

63

64

50 ax.1 1,2 litre

67

61

ax.2 1,0 litre

61

60

63

31

59

31

63

63

Frame complete with cables (shown without console)

Foldout 2

0,4 litre

67

100

104

105

64

3

103

101

8

113

102 Do not loosen these screws

Do not loosen these screws

3

110

109

18

66

17

16

35 Nm

108

107

112

Lower arm (shown without cables)

111

4,1 Nm

106

Lower arm complete with cables (shown without cover)

Foldout 3

0,35 litre oil

182

151

152

0,2 litre oil

180

182

156

159

176

162

162

164

163

4,1 Nm

112

169

153

28 Nm

154

170

171

172

3 Nm

173

181

108

157

35 Nm

158

161

112

111 6 Nm

160

112

4,1 Nm

163

Upper arm (shown without cables)

112

4,1 Nm

111

166

165

6 Nm

169

112

163

4,1 Nm

175

8

174

12

Foldout 4

177

179

168

167

150

20

165

3

Upper arm with cables (shown without cover)

178

155

Upper arm complete

Foldout 5

Manipulator Circuit Diagram

3HAC 6813-3

CONNECTION POINT LOCATIONS Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

102

Manipulator Circuit Diagram

3HAC 6813-3

SERIAL MEASUREMENT BOARD Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

103

Manipulator Circuit Diagram

3HAC 6813-3

MOTOR AXIS 1 - 3 Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

104

Manipulator Circuit Diagram

3HAC 6813-3

FEED-BACK AXIS 1 - 3 Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

105

Manipulator Circuit Diagram

3HAC 6813-3

MOTOR AXIS 4 - 6 Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

106

Manipulator Circuit Diagram

3HAC 6813-3

FEED-BACK AXIS 4 - 6 Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

107

Manipulator Circuit Diagram

3HAC 6813-3

CUSTOMER CONNECTIONS Product Manual IRB 140 M2000

No. of Sheets 8

Sheet no.

108

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.

© ABB Robotics Products AB Article number: 3HAC 7564-1 Issue: M2000 ABB Robotics Products AB S-721 68 Västerås Sweden