ABB-Robot IRB-2400 M2000 ProductManual En

8/11/2019 ABB-Robot IRB-2400 M2000 ProductManual En

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Product Manual

3HAC 7626-1 rev.1 / M200

IRB 2400



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

In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arisingfrom 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 withoutABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a thirdparty 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 currentcharge.

© ABB Robotics Products AB

Article number: 3HAC 7626-1Issue: M2000

ABB Robotics Products ABS-721 68 Västerås

Sweden



Table of Contents 1 Introduction

2 Product Specifications

3 Safety

4 Certificates

5 Configuration list

6 Fault Tracing Guide

7 Decommissioning

8 System Description

Control 9 Installation & Commissioning

10 Maintenance

11 Spare Parts List12 Circuit Diagrams

Mani ulato 13 Installation & Commissioning

14 Maintenance

15 Repairs

16 Spare Parts

17 Circuit Diagrams





Introduction

CONTENTSPage

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

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

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

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

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

1.4.1 Manipulator...................................................................................... 6

1.4.2 Controller ......................................................................................... 10

1.4.3 Electronics unit ................................................................................ 10

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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 bothmechanical and electrical systems. The manual does not in any way assume totake the place of the maintenance training course offered by ABB FlexibleAutomation.

Anyone reading this manual should also have access to the User’s Guide.

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

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

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

Servicing and maintenance routines are described in the chapter onMaintenance.

1.2 What you must know before you use the RobotNormal maintenance and repair work

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

The power supply

Must always be switched off whenever work is carried out in the controllercabinet. Note that even though the power is switched off, the orange-colouredcables may be live. The reason for this is that these cables are connected toexternal equipment and are consequently not affected by the mains switch onthe controller.

Circuit boards - printed boards and components

Must never be handled without Electro-Static Discharge (ESD) protection inorder not to damage them. Use the wrist strap located on the inside of thecontroller door.

All personnel working with the robot system must be very familiar with the

safety regulations outlined in the chapter on Safety. Incorrect operation candamage the robot or injure someone.



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 asexamples. For exact identification see the plates on the robot in question.

IRB 6400R

Identification plate showinthe IRB 6400R / M2000

IRB 140(0)

IRB 640IRB 840/A

IRB 340

IRB 4400IRB 2400

Made in SwedenS-721 68 Västerås Sweden

ABB Robotics Products AB

Type:

Robot version:

Man. order:

Nom. load

Serial. No:

Date of manufacturing:

Net weight

2,5.120 : 2060 kg

2.5-150 : 2060 kg

2,5-200 : 2230 kg

IRB 6400R M2000

IRB 6400R/2.5-150

XXXXXX

See instructions

6400R-XXXX

2000-XX-XX

2,8-150 : 2240 kg

2,8-200 : 2390 kg

3.0-100 : 2250 kg

IRB 140



Introduction

.

Figure 2 Identification plate on the controller.

Figure 3 Example of a label on a BaseWare O.S diskette.

Made in SwedenS-721 68 Västerås Sweden


Type:

Robotversion:

Voltage: 3x 400V

Powe

IRB6400RM99

IRB6400R/ 2.5-150


64-00000

System Key S4C 3.1

Program No 3 HAB2390-1/

Property of ABB Västerås/ Sweden. All rights reserved.

Reproduction, modification,



Introduction

1.4 Structure Manipulator

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

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

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

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

Motor axis 5 Motor axis 6

Motor axis 4

Axis 2

Axis 1

Motor axis 1

Axis 3

Motor axis 2

Motor axis 3

Axis 4 Axis 5

Axis 6

Upper arm

Lower arm

Base

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Introduction

Figure 5 The motion patterns of the IRB 2400.

Figure 6 The motion patterns of the IRB 4400

Motor unit axis 4 Motor unit axis 5

Upper arm

Motor unit and gearbox axis 2

Base


Lower arm

Axis 1

Axis 2

Axis 3 Axis 4

Axis 5

Axis 6

Motor unit axis 6


Motor axis 4 Motor axis 5 Motor axis 6

Axis

Axis 1

Motor axis

Axis 3

Motor axis

Motor axis

Axis 4 Axis 5

Axis 6

Upper arm

Lower arm

Base



Introduction

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


Base

Axis 1 Lower arm

Axis 2

Motor axis 2

Motor axis 6

Axis 5

Axis 3 Upper arm


Motor axis 1

Motor axis 3

Axis4

Axis 6

Axis 1

Axis 2

Axis 3

Axis 6

Upper arm

Lower arm

Motor axis 2

Motor axis 6

Motor axis 1

Motor axis 3



Introduction

Figure 9 The motion patterns of the IRB 840/A

4(C)-axis

1(X)-axis

2(Y)-axis

3(Z)-axis

Motor 1(X)-axis

Motor 4(C)-axis

Motor 3(Z)-axis

Motor 2(Y)-axis



Introduction

.



Axis 2

Axis 1

Axis 3

Axis 4,

Bars (x3)

Upper arm (x3)

telescopic shaft Swivel

Axis 2

Axis 3

X

Y

Z

Base box

(option)

Motorsencapsulated


Motor axis 6

Axis 2

Axis 1

Motor axis 1

Axis 3

Motor axis 3

Axis 4

Axis 5

Axis 6

Upper arm

Base

Lower arm

Motor axis 2



Product SpecificationS4Cplus

3HAC 9039-1 / M2000BaseWare OS 4.0



The information in this document is subject to change without notice and should not be construed as acommitment by ABB Robotics AB. ABB Robotics AB assumes no responsibility for any errors that mayappear in this document.

In no event shall ABB Robotics AB be liable for incidental or consequential damages arising from useof this document or of the software and hardware described in this document.

This document and parts thereof must not be reproduced or copied withoutABB Robotics AB´s written permission, and contents thereof must not be imparted to a third party norbe 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 9039-1Issue: M2000/BaseWare OS 4.0

ABB Robotics ABS-721 68 Västerås

Sweden



Product Specification S4Cplus

CONTENTSPage

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................................................................................................. 161.10 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............................................................................................... 20Motion 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

System signals........................................................................................................ 26

1.14 Communication .................................................................................................... 27

2 Specification of Variants and Options........................................................................... 29

3 Index................................................................................................................................. 41



Description

1 Description

1.1 Structure

The controller contains the electronics required to control the manipulator, externalaxes and peripheral equipment.

The controller also contains the system software, i.e. the BaseWare OS (operatingsystem), 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 < 70 dB (A) Leq (acc. tothe working space Machinery directive 98/37/EEC)

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

Teach pendant Operator´s panel

Disk driveMains switch



Description

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

200

950980 *

500

500

820

Lifting points * Castor wheels, Option 126

800

250

Extended cover

Option 123

Cabinet extension

Option 124

for forklift

200

Air distance to wall

800

623

71 52



Description

1.2 Safety/Standards

The robot conforms to the following standards:

EN 292-1 Safety of machinery, terminologyEN 292-2 Safety of machinery, technical specifications

EN 954-1 Safety of machinery, safety related parts of controlsystems

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, mechanicalinterface

ISO 9787 Manipulating industrial robots, coordinate systemsand 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 RoboticEquipment

CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - GeneralSafety Requirements

The robot complies fully with the health and safety standards specified in the EEC’sMachinery Directives.

The robot controller is designed with absolute safety in mind. It has a dedicated safetysystem based on a two-channel circuit which is monitored continuously. If anycomponent fails, the electrical power supplied to the motors shuts off and the brakes engage.

Safety category 3Malfunction of a single component, such as a sticking relay, will be detected at the nextMOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faultysection 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 modeThe robot can be operated either manually or automatically. In manual mode, the robotcan only be operated via the teach pendant, i.e. not by any external equipment.

Reduced speedIn 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 ofthe 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 inmanual mode. The enabling device consists of a switch with three positions, meaningthat all robot movements stop when either the enabling device is pushed fully in, or



Description

Safe manual movementThe robot is moved using a joystick instead of the operator having to look at the teachpendant to find the right key.

Over-speed protection

The speed of the robot is monitored by two independent computers.

Emergency stopThere is one emergency stop push button on the controller and another on the teachpendant. Additional emergency stop buttons can be connected to the robot’s safety chaincircuit.

Safeguarded space stopThe controller has a number of electrical inputs which can be used to connect externalsafety equipment, such as safety gates and light curtains. This allows the robot’s safetyfunctions to be activated both by peripheral equipment and by the robot itself.

Delayed safeguarded space stopA delayed stop gives a smooth stop. The robot stops in the same way as at a normalprogram stop with no deviation from the programmed path. After approx. 1 second thepower supplied to the motors shuts off.

Collision detectionIn 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 spaceThe movement of each axis can be restricted using software limits.There are safeguarded space stops for connection of limit switches to restrict the workingspace.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. Whenthe button is released the robot will stop. The hold-to-run function makes program testingsafer.

Fire safetyBoth the manipulator and control system comply with UL’s (Underwriters Laboratory)tough requirements for fire safety.

Safety lampAs 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.



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).

.

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 andfunction keys. No previous programming or computer experience is required to learnhow 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 thecomplete programming language, is in English or, if preferred, some other majorlanguage. (Available languages, see options on page 32).

DisplayDisplays all information during programming, to change programs, etc.16 text lines with 40 characters per line.

Motion keysSelect the type of movement when jogging.

Navigation keysUsed to move the cursor within a window on the display and enter data.

Menu keysDisplay pull-down menus, see Figure 4.

Function keysSelect the commands used most often.

Window keysDisplay one of the robot’s various windows.These windows control a number of different functions:

- Jog (manual operation)

- Program, edit and test a program

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2

Hold-to-run

Enabling

P4

P5

device

Joystick

Function keys

Motion keysMenu keys

Window

Navigation keys

Display

keys

Cable 10 m

Emergency stopbutton



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/closegripper) or to activate a system input.

Hold-to-runA push button which must be pressed when running the program in manual mode withfull speed.

Enabling deviceA 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 theMOTORS OFF state.

JoystickThe joystick is used to jog (move) the robot manually; e.g. when programming therobot.

Emergency stop buttonThe robot stops immediately when the button is pressed in.

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

Using the joystick, the robot can be manually jogged (moved). The user determines thespeed 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:

Inputs/Outputs

File

Value

1

0

1

0

1

1

13

Edit View

1 0

4(6)Name

di1

di2

grip1

grip2

clamp3B

feeder

progno

1 Goto ...2 Goto Top

3 Goto Bottom

Menu keys

I/O list

Menu

Line indicator

Cursor

Function keys



Description

- Programming

- System setup

- Service and installation

Operator’s panel

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

Operating mode selector

MOTORS ON

Continuous light

Fast flashing light (4Hz)

Ready for program execution

Note: The motors have been switched on

=

= One of the safeguarded space stops is active

Emergency stopIf pressed in,

MOTORS ON buttonand indicating lamp

Duty time counter

The robot is not calibrated or the revolution counters

Slow flashing light (1 Hz)Note: The motors have been switched off

Indicates the operating time forthe manipulator (released brakes)

Operating mode selector

Automatic mode

Manual modeat reduced speed

100% Manual modeat full speed

= Running production

Programming and setupMax. speed 250 mm/s (600 inches/min.)

=

As optional:

Testing at full program speed=

are not updated

pull to release

=

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

Equipped with this mode,the robot is not approvedaccording to ANSI/UL



Description

Both the operator’s panel and the teach pendant can be mounted externally, i.e. outsidethe 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.



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, andit is thus divided into three areas:

- system software

- system software execution data

- user RAPID programs, about 5.5 MB, see Figure 6 (when installing differentoptions, 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 dataincluding 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 thesystem specific data including the user program, see Figure 6, will be stored on theflash 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

Release storage

20 MB

System data anduser program

10 MB

Mass memory areaavailable for

Systemsoft ware

Data

User RAPIDprogram 5.5 MB

the user

Power on -restore

Poweroff -store



Description

Several different systems, i.e. process applications, may be installed at the same timein the controller, of which one can be active. Each such application will occupy another10 MB of the flash memory for system data. The release storage area will be in commonas long as the process applications are based on the same release. If two differentreleases should be loaded, the release storage area must also be doubled.

For RAPID memory consumption, see RAPID Developer’s Manual. As an example, aMoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in theinstruction (marked with ‘*’) and 168 bytes if a named robtarget is used. In the lattercase, the CONST declaration of the named robtarget consumes an additional 280 bytes.

Additional software options will reduce the available user program memory, most ofthem 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 MBdepending on the number of simultaneous welding guns.

1.5 Installation

The controller is delivered with a standard configuration for the correspondingmanipulator, and can be operated immediately after installation. Its configuration isdisplayed in plain language and can easily be changed using the teach pendant.

Operating requirements

Protection standards IEC529Controller electronic IP54Controller air ducts IP 30

Explosive environmentsThe controller must not be located or operated in an explosive environment.

Ambient temperatureController 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 humidityTransportation, storage and operation Max. 95% at constant temperature

Power supply

Mains voltage 200-600 V, 3p (3p + N for certainoptions

Mains voltage tolerance +10%,-15%

Mains frequency 48.5 to 61.8 Hz

Rated power (transformer size):IRB 140, 1400, 2400 4.5 kVAIRB 340, 14001, 24001,4400, 6400 7.8 kVAExternal axes drives in separate cabinet 7.2 kVA

Computer system backup capacity 20 sec (rechargeable battery)at power interrupt



Description

Configuration

The robot is very flexible and can, by using the teach pendant, easily be configured tosuit the needs of each user:

Authorisation Password protection for configuration and programwindowMost common I/O User-defined lists of I/O signalsInstruction pick list User-defined set of instructionsInstruction builder User-defined instructionsOperator dialogs Customised operator dialogsLanguage All text on the teach pendant can be displayed in

several languagesDate and time Calendar supportPower on sequence Action taken when the power is switched onEM stop sequence Action taken at an emergency stopMain start sequence Action taken when the program is

starting from the beginningProgram start sequence Action taken at program startProgram stop sequence Action taken at program stopChange program sequence Action taken when a new program is loadedWorking space Working space limitationsExternal axes Number, type, common drive unit, mechanical

unitsBrake delay time Time before brakes are engagedI/O signal Logical names of boards and signals, I/O mapping,

cross connections, polarity, scaling, default value atstart up, interrupts, group I/O

Serial communication 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 ofappropriate 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.



Description

Movements

A sequence of movements is programmed as a number of partial movements betweenthe positions to which you want the robot to move.

The end position of a movement is selected either by manually jogging the robot to thedesired 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 sizeof the deviation is defined independently for the TCP, the tool orientation andthe external axes.

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 beautomatically 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 usinga 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 beedited using these commands.

No reprogramming is necessary when processing left-hand and right-hand parts, sincethe program can be mirrored in any plane.

Stop point Fly-by point

User-definable distance (in mm)



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 beused.

Testing programs

Several helpful functions can be used when testing programs. For example, it ispossible 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 theoperator is automatically displayed during automatic operation.

The operation procedure can be customised to suit the robot installation by means ofuser-defined operating dialogs.

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.

Front A Front B Front C Other Service

Select program to run:



Description

is switched on, at program start and on other occasions. This allows you to customiseeach 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 therobot 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 beeasily restarted from where you left off. Digital outputs are also set automatically to thevalue prior to the power failure.

1.8 The Rapid Language and Environment

The Rapid language is a well balanced combination of simplicity, flexibility andpowerfulness. 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 whenstepping 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 definedpick 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 specificinstallation in order to minimise down time. Examples:

- Error Handlers (automatic recovery often possible without stoppingproduction).

- Restart on Path.

- Power failure restart.

- Service routines



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 beendesigned to make it as easy to service as possible:

- The controller is enclosed, which means that the electronic circuitry isprotected 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 todetect error chains and provides the background for any downtime. The log canbe 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 andfunctions.

- 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 thestandard error system. Error messages and recovery procedures are displayed in plainlanguage.

For detailed information on maintenance procedures, see Maintenance section in theProduct Manual.

1.11 Robot Motion

Motion concepts

QuickMoveTM

The QuickMoveTM concept means that a self-optimizing motion control is used. Therobot automatically optimizes the servo parameters to achieve the best possibleperformance 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 andvelocity.

M i l ti i l bt i d ( l ti b d d



Description

when handling fragile parts).

- The number of adjustments that have to be made to achieve the shortest possiblecycle time is minimized.

TrueMoveTM

The TrueMoveTM concept means that the programmed path is followed – regardless ofthe speed or operating mode – even after an emergency stop, a safeguarded stop, aprocess 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 thatfacilitates jogging, program adjustment, copying between robots, off-lineprogramming, sensor based applications, external axes co-ordination etc. Full supportfor TCP (Tool Centre Point) attached to the robot or fixed in the cell (“StationaryTCP”).

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

The world coordinate system defines a reference to the floor, which is the startingpoint for the other coordinate systems. Using this coordinate system, it is possible to

ObjectZ

Y

X

World coordinates

UserZ

Z

Y

Y

X

X

coordinates

coordinates

X

Y

Z

Base coordinates

Y

Z

X

X

Base coordinates

Tool coordinates

Tool Centre Point (TCP)

Axis 1

Y

Z

XZ

Y

Axis 3

Axis 3

Axis 1

Axis 2

X

Y

Tool coordinates

Tool Centre Point (TCP)



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 workpiecemanipulator.

The object coordinate system specifies how a workpiece is positioned in a fixture orworkpiece manipulator.

The coordinate systems can be programmed by specifying numeric values or joggingthe 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 andorientation. This means that even if a tool is changed because it is damaged, the oldprogram 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 beredefined.

Stationary TCP

When the robot is holding a work object and working on a stationary tool, it is possibleto define a TCP for that tool. When that tool is active, the programmed path and speedare related to the work object.

Program execution

The robot can move in any of the following ways:

- Joint motion (all axes move individually and reachthe 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 imperfectionin processed objects can occur.

If the location of a workpiece varies from time to time, the robot can find its positionby 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 coordinatesystems mentioned above).

- Reoriented around the TCP.

It is possible to select the step size for incremental jogging. Incremental jogging can beused to position the robot with high precision, since the robot moves a short distanceeach time the joystick is moved



Description

During manual operation, the current position of the robot and the external axes can bedisplayed on the teach pendant.

Singularity handling

The robot can pass through singular points in a controlled way, i.e. points where twoaxes coincide.

Motion Supervision

The behaviour of the motion system is continuously monitored as regards position andspeed level to detect abnormal conditions and quickly stop the robot if something is notOK. A further monitoring function, Collision Detection, is optional (see option “LoadIdentification and Collision Detection”).

External axes

Very flexible possibilities to configure external axes. Includes for instance highperformance 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 bigload 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 willadopt a spring-like behaviour.

1.12 External Axes

The robot can control up to six external axes. These axes are programmed and movedusing 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-axislinear 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 unitmounted in the robot cabinet or in a separate enclosure. See Specification of Variantsand Options.



Description

Resolver Connected directly to motor shaftTransmitter type resolverVoltage ratio 2:1 (rotor: stator)

Resolver supply 5.0 V/4 kHz

Absolute position is accomplished by battery-backed resolver revolution counters inthe 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 andupwards must be placed in a separate cabinet according to Figure 10.

Figure 10 Outline diagram, external axes.

alt.

Not supplied on delivery

Not supplied

on delivery

Not supplied on delivery

MeasurementSystem 1User designed cabinet

(non-ABB drives)

SMB

SMB

Measurement System 2

ABB drives

Drive system 2

Single external axis

Multiple external axis

Motor channel

Serial signals for

measurement anddrive system





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 withoutneed the for physical hardware).

- Accurate coordination with motion.

Signals can be assigned to special system functions, such as program start, so as to beable 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, thetrap routine starts executing. Following this, normal program executionresumes. 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 berun in parallel with the actual robot program. Requires Multitasking option, seeProduct 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 theupper 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.



Description

Distributed I/O

The total number of logical signals is 1024 per DeviceNet bus (inputs or outputs, groupI/O, analog and digital including field buses)

CAN1 CAN2 (option)

Max. total no of units* 20 (including SIM units) 20Data rate (fixed) 500 Kbit/s 125/250/500 Kbit/s.Max. total cable length 100 m trunk + 39m drop up to 1000mCable type (not included) According to DeviceNet specification release 1.2

* Max. four units can be mounted inside the cabinet.

Signal data

Permitted customer 24 V DC load max. 7,5 A

Digital inputs (option 201/203)24 V DC Optically-isolated

Rated voltage: 24 V DC

Logical voltage levels: “1” 15 to 35 V“0” -35 to 5 VInput current at rated input voltage: 6 mA

Type of unit Option no.

Digital Analog

Power supplyIn Out Voltage

inputs

Voltage

output

Current

output

Digital I/O 24 VDC 20x 16 16 Internal/External1

1. The digital signals are supplied in groups, each group having 8 inputs or outputs.

Digital I/O 120 VAC 25x 16 16 Internal/External

Analog I/O 22x 4 3 1 Internal

AD Combi I/O 23x 16 16 2 Internal/External1

Relay I/O 26x 16 16 Internal/External1

Allen-Bradley

Remote I/O Slave281 1282

2. To calculate the number of logical signals, add 2 status signals for RIO unit and 1 for Interbus-S

and Profibus DP.

128

Interbus-S Slave 284-285 642 64

Profibus DP Slave 286-287 1282 128

Simulated I/O3

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.

100 100 30 30

Encoder interface

unit4

4. Dedicated for conveyor tracking only.

288-289 1



Description

Time delays: hardware 5−15 mssoftware ≤ 3 ms

Time variations: ± 2 ms

Digital outputs (option 201/203)24 V DC Optically-isolated, short-circuit protected, supply polarity protection

Voltage supply 19 to 35 VRated voltage 24 V DCLogical voltage levels: “1” 18 to 34 V

“0” < 7 VOutput current: max. 0.5 APotential difference: max. 500 VTime delays: hardware ≤ 1 ms

software ≤ 2 msTime variations: ± 2 ms

Relay outputs (option 205)Single pole relays with one make contact (normally open)Rated voltage: 24 V DC, 120 VACVoltage range: 19 to 35 V DC

24 to 140 V ACOutput current: max. 2 APotential difference: max. 500VTime intervals: hardware (set signal) typical 13 ms

hardware (reset signal) typical 8 mssoftware ≤ 4 ms

Digital inputs

120 V AC (option 204)Optically isolatedRated voltage 120 V ACInput voltage range: “1” 90 to 140 V ACInput voltage range: “0” 0 to 45 V ACInput current (typical): 7.5 mATime intervals: hardware ≤ 20 ms

software ≤ 4 msDigital outputs120 V AC (option 204)

Optically isolated, voltage spike protectionRated voltage 120 V AC

Output current: max. 1A/channel, 12 A16 channelsor

max. 2A/channel, 10 A16 channels(56 A in 20 ms)

min. 30mAVoltage range: 24 to 140 V ACPotential difference: max. 500 VOff state leakage current: max. 2mA rmsOn state voltage drop: max. 1.5 V

Time intervals: hardware ≤ 12 mssoftware ≤ 4 ms



Description

Analog inputs (option 202)Voltage Input voltage: +10 V

Input impedance: >1 MohmResolution: 0.61 mV (14 bits)

Accuracy: +0.2% of input signal

Analog outputs (option 202)VoltageOutput voltage: +10 V

Load impedance: min. 2 kohmResolution: 2.44 mV (12 bits)

CurrentOutput current: 4-20 mALoad impedance: min. 800 ohmResolution: 4.88 µA (12 bits)

Accuracy: +0.2% of output signal

Analog outputs (option 203)Output voltage (galvanically isolated): 0 to +10 V

Load impedance: min. 2 kohmResolution: 2.44 mV (12 bits)Accuracy: ±25 mV ±0.5% of output

voltagePotential difference: max. 500 VTime intervals: hardware ≤ 2.0 ms

software ≤ 4 ms

System signals

Signals can be assigned to special system functions. Several signals can be given thesame functionality.

Digital outputs Motors on/off Executes programErrorAutomatic modeEmergency stopRestart not possibleRun chain closed

Digital inputs Motors on/off Starts program from where it is

Motors on and program startStarts program from the beginningStops programStops program when the program cycle is readyStops program after current instructionExecutes “trap routine” without affecting status of stoppedregular program1 Loads and starts program from the beginning1

Resets errorResets emergency stopSystem reset

Analog output TCP speed signal1. Program can be decided when configuring the robot.



Description

1.14 Communication

The controller has three serial channels for permanent use - two RS232 and oneRS422 Full duplex- which can be used for communication point to point withprinters, 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 withspeed 19200 bit/s).

Figure 12 Point-to-point communication.

The controller has two Ethernet channels, one can be used at 10 MB/s, the other at upto 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 possibleto use OPC, ActiveX, and other APIs for integration with Window applications

- Boot/upgrading of controller software via the network or a portable PC.

Temporary

Permanent

RS 232 or

Ethernet 10 MB/s

10 MB

Ethernet up to 100 MB/s

10 MB10 MB



Description



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 softwareoptions, 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 “ElectromagneticCompatibility” 89/336/EEC. This option is required by law for end users in theEuropean Union.

UNDERWRITERS LABORATORY

695 UL Listed, certificate on product level.Underwriters Laboratories Inc. has tested and examined the finished completeproduct, i.e. manipulator and controller, and determined that the product fulfils thestipulated 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 theproduct, manipulator and controller, and determined that they fulfil the stipulatedsafety standards.Not available for IRB 340.

2 CONTROL SYSTEM

CABINET

Variant

111 Standard cabinet with upper cover.

112* Prepared for ArcitecNot 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

t f th bi t ft d li




123* Standard cabinet with 250 mm extension. The height of the cover increases theavailable 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 plateinside. (See Figure 14).

The cabinet extension is opened via a front door and it has no floor. The upper part ofthe standard cabinet is therefore accessible.This option cannot be combined with options 141 together with 145.

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., issupplied.External enclosure is not supplied.

183 External, mounted in a box. (See Figure 16)

Shaded area 40x40(four corners) not available

705

730

for mounting




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

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

184

224180

140

193196

70

62

45o

External panel enclosure

(not supplied)

M8 (x4)

Connection to

Holes forflange

Holes foroperator’s panel

Holes forteach pendant holder

the controller

90

1555 (x2)

Teach pendantconnection

200

240Required depth 200 mm

M4 (x4)

96

223

337

370

M5 (x4) for fastening of box

Connection flange




OPERATOR’S PANEL CABLE

185 15 m186 22 m187 30 m

DOOR KEYS

461 Standard

462 Doppelbart

463 Square outside 7 mm

464 EMKA DB

466 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 PENDANT601 Teach pendant with back lighting

Teach pendant language:

611 English612 Swedish613 German614 French615 Spanish617 Danish618 Italian

619 Dutch620 Japanese621 Czech

Extension cable for the teach pendant:

606 10 mThis can be connected between the controller and the connector on the teachpendant’s cable.

A maximum of two extension cables may be used; i.e. the total length of cable betweenthe controller and the teach pendant should not exceed 30 m.

607 20 m




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 permissiblein each connection.

151- Voltage Voltage Voltage

163 200 V220 V400 V 400 V440 V 440 V

475 V 475 V500 V 500 V

525 V600 V

MAINS CONNECTION TYPE

The power is connected either inside the cabinet or to a connector on the cabinet’s left-hand 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 inaccordance 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. Includesdoor interlock. Interrupt capacity 14 kA.

144 Servo disconnector.This option adds a mechanical switch to the two series connected motors oncontactors. The switch is operated by the same type of handle as the rotarymains 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




I/O INTERFACES

The standard cabinet can be equipped with up to four I/O units. For more details, see page 22

Figure 19 I/O unit and screw terminal locations.

Cabinet view from above

X9 (SIO2)

X7 (CAN 1.3) X8 (CAN 2)

X15 (CAN1.1)

X6 (CAN 1.2)

Computersystem

Base Connector Unit

XP8

XT21 XP6

XP5 XP58

I/O Units (X4)

X 1 - X 4Safety Signals

X10 (SIO1)

XT 31(24V I/O)

(COM2)

Panel Unit

Manipulator connections115/230 VAC

Connection toCustomer power

Customer signals

Connection toPosition switches




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 digitaloutputs. 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 partof the cabinet (see Figure 19).

252 External connection

The signals are connected via 64-pole standard industrial connector in accordancewith DIN 43652. The connector is located on the left-hand side of the controller.Corresponding customer part is included.

SAFETY SIGNALS

206 Internal connectionThe 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 accordancewith DIN 43652. The connector is located on the left-hand side of the controller.Corresponding customer part is included.

DEVICENET ON LEFT WALL

245 DeviceNetConnection 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/OUp to 128 digital inputs and outputs, in groups of 32, can be transferred serially to aPLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces thenumber of I/O units that can be mounted in cabinet by one. The field bus cables areconnected 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 PLCequipped with an InterBus-S interface. The unit reduces the number of I/O units that






Figure 20 Dimensions for units 221-225.

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 areconnected to a standard industrial 64-pin female connector, in accordance with DIN43652, on the left-hand side of the cabinet. (Male connector is also supplied.)

391 Drive unit CThe drive unit is part of the DC-link. Recommended motor type see Figure 22.Not available for IRB 640, 6400R, 6400S.

392 Drive unit TThe 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

195

203 49

EN 50022 mounting rail

49115

170

EN 50022 mounting rail




394 Drive unit T+GTA combination of 392 and 393.Not available for IRB 4400, 640, 6400R, 6400S

395 Drive unit C+GT

A combination of 391 and 393Not available for IRB 4400, 640, 6400R, 6400S

396 Prepared for drivesNo 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 UThe drive unit is part of the DC-link. Recommended motor types see Figure 22.Not available for IRB 140, 1400, 2400, 4400, 640

365 TrackmotionOnly 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 standardcabinet. 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 therobot 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.

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

374 Drive unit GT + ECB375 Drive unit GT + GT + ECB

376 External drive systemIndustrial connector and 7 m cable for DMC/FBU drive unit supplied byAtlas Copco Controls.The option Advanced Motion is required.




Figure 22 Motor selecting table.

EQUIPMENT

Manipulator cable, external connectors

653 Standard

654 Metal braidedOnly together with 641 or 642.Not available for IRB 340 and protection foundry.

655 Foundry

Cable length

641 7m642 15 m, not available for IRB 140643 22 m, not available for IRB 140644 30 m, not available for IRB 140649 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 formaintenance purposes.The maximum load permitted is 500 VA (max. 100 W can be installed inside thecabinet).

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 forSweden, Germany and other countries.

Drive unit data Max current Rated current Motor type1

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)

U 11 - 55A rms 24A rms M, L

G 6 - 30A rms 16A rms S, M, LT 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




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 neutralconnection and a 230 V service socket.Note! Connection before mains switch is not in compliance with some nationalstandards, NFPL 79 for example.

MEMORY

Removable mass memory

320 Floppy driveThe disk drive normally works well at temperatures up to 40oC (104oF). The disk drivewill not deteriorate at higher temperatures but there will be an increase in the numberof reading/writing problems as the temperature increases.

Extended mass memory

310 Flash disc 128 Mb. Standard is 64 Mb



Index

3 Index

A

absolute measurement 16Allen-Bradley Remote I/O 22, 24, 35analog signals 22, 26automatic operation 15

B

backupcomputer system backup 12memory 11

Big Inertia 20

C

cabinet wheels 30communication 27concurrent I/O 23configuration 12, 13, 22connection 40

mains supply 33cooling device 3

coordinate systems 18cross connections 22cursor 7

D

DeviceNet 35diagnostics 17digital signals 22, 24display 7distributed I/O 24

E

editingposition 14programs 14

emergency stop 6, 7enabling device 5

display 7Encoder interface unit 24, 36event routine 15

extended memory 11external axes 20external panel 30

F

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

H

hold-to-run control 6humidity 12

I

I/O 22I/O units 23incremental jogging 19inputs 22installation 12Interbus-S Slave 24, 35interrupt 23

J

jogging 19

joystick 8

L

language 13lighting

connection 40teach pendant 32

M

mains supply 33

mains switch 33mains voltage 33maintenance 17manipulator cable 39mass memory 11memory

backup 11extended 11flash disk memory 11mass storage 11RAM memory 11

menu keys 7mirroring 14



Index

motion 17motion keys 7motion performance 17

Motion Supervision 20Multitasking 23

N

navigation keys 7noise level 3

O

operating mode 9operating mode selector 9, 32

operating requirements 12operation 7operator dialogs 13operator’s panel 9, 30options 29outputs 22overspeed protection 6

P

password 13, 15

performance 17PLC functionality 23position

editing 14execution 19programming 14, 19

position fixed I/O 23power supply 12production window 15Profibus DP Slave 24, 36program

editing 14testing 15

programming 13protection standards 12

Q

QuickMove 17

R

Rapid Language 16reduced speed 5

S

safeguarded space stop 6delayed 6

safety 5safety lamp 6serial communication 27service 17service outlets 39, 40signal data 24singularity handling 20Soft Servo 20space requirements 3standards 5

stationary TCP 19stop point 14structure 3system signals 26

T

TCP 19teach pendant 7

cable 32lighting 32

temperature 12testing programs 15transformer 33trap routines 23troubleshooting 17TrueMove 18

U

user-defined keys 8

V

variants 29volume 3

W

window keys 7windows 7working space

restricting 6



Product Specification IRB 2400

3HAC 9112-1 / M2000







© ABB Robotics AB

Article number: 3HAC 9112-1Issue: M2000


Sweden




CONTENTSPage

1 Description ....................................................................................................................... 31.1 Structure.................................................................................................................. 3

Different robot versions ......................................................................................... 4

Definition of version designation........................................................................... 4

1.2 Safety/Standards..................................................................................................... 7

1.3 Installation .............................................................................................................. 9

Operating requirements.......................................................................................... 9

Mounting the manipulator...................................................................................... 10

Load diagrams........................................................................................................ 11

Mounting equipment.............................................................................................. 15

1.4 Maintenance and Troubleshooting ......................................................................... 18

1.5 Robot Motion.......................................................................................................... 19

Performance according to ISO 9283...................................................................... 21

Velocity .................................................................................................................. 21

Resolution .............................................................................................................. 21

1.6 Signals .................................................................................................................... 21

2 Specification of Variants and Options........................................................................... 23

3 Accessories ....................................................................................................................... 27

4 Index................................................................................................................................. 29






Description

1 Description

1.1 Structure

IRB 2400 is a 6-axis industrial robot, designed specifically for manufacturingindustries that use flexible robot-based automation. The robot has an open structurethat is specially adapted for flexible use, and can communicate extensively withexternal systems.

The robots with Foundry protection are designed for harsh environment and havespecial surface treatment and paint for excellent corrosion protection. The connectorsare designed for severe environment, and bearings, gears and other sensitive parts arehigh protected. The high degree of tightness makes the IRB 2400/10 and /16 steam

washable.

The robot is equipped with the operating system BaseWare OS. BaseWare OS controlsevery aspect of the robot, like motion control, development and execution ofapplication programs communication etc. See Product Specification S4Cplus.

For additional functionality, the robot can be equipped with optional software forapplication support - for example gluing and arc welding, communication features -network communication - and advanced functions such as multitasking, sensor controletc. For a complete description on optional software, see the Product SpecificationRobotWare Options.

Figure 1 The IRB 2400 manipulator has 6 axes.

Axis 6

Axis 1

Axis 3

Axis 5Axis 4

Axis 2



Description

Different robot versions

The IRB 2400 is available in different versions depending on its handling capacity andenvironment protection. The following robot versions are available, floor mounting orinverted:

Definition of version designation

IRB 2400 Application / Version - Handling capacity

Manipulator weight 380 kg

Airborne noise level:The sound pressure level outside < 70 dB (A) Leq (acc. tothe working space Machinery directive 89/392 EEC)

Robot Versions

IRB 2400L IRB 2400FL

IRB 2400/10 IRB 2400F/10

IRB 2400/16 IRB 2400F/16

Prefix Description

Version L Long arm

Application F Manipulator adapted for use in harsh environ-ments (e.g. foundry)

Handling capacity yy Indicates the maximum handling capacity (kg)



Description

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

290

1225

R=448

260

123

65

100

723

305

1730

389

150

855

615

180

870

360

IRB 2400L

600

R=76

A - A

444

446

268 251

454

CL

R=347

R=330

A

A

176 138

180



Description

Figure 3 View of the manipulator from the side, rear and above (dimensions in mm).

180

135

306

133755 85

IRB 2400/10

A

100

305

CL

723

85

78(163)

A

IRB 2400/16

1065

A - A

R=98

180

R=448

600

1564

615

705

446 454

R=347

R=330

444

389

176 138268 251





Description

that all robot movements stop when either the enabling device is pushed fully in, orwhen it is released completely. This makes the robot safer to operate.

Safe manual movementThe robot is moved using a joystick instead of the operator having to look at the teach

pendant to find the right key.

Over-speed protectionThe speed of the robot is monitored by two independent computers.

Emergency stopThere is one emergency stop push button on the controller and another on the teachpendant. Additional emergency stop buttons can be connected to the robot’s safetychain circuit.

Safeguarded space stopThe 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 safetyfunctions to be activated both by peripheral equipment and by the robot itself.

Delayed safeguarded space stopA delayed stop gives a smooth stop. The robot stops in the same way as at a normalprogram stop with no deviation from the programmed path. After approx. 1 second thepower supplied to the motors shuts off.

Collision detection (option)In case an unexpected mechanical disturbance like a collision, electrode stik etcappears, the robot will stop and slightly back off from its stop position.

Restricting the working spaceThe movement of each axis can be restricted using software limits.Axes 1-2 can also be restricted by means of mechanical stops and axis 3 by anelectrically switch (option).

Hold-to-run control“Hold-to-run” means that you must depress the start button in order to move the robot. Whenthe button is released the robot will stop. The hold-to-run function makes program testingsafer.

Fire safetyBoth 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 acti-vated when the motors are in the MOTORS ON state.



Description

1.3 Installation

The same version of the robot can either be mounted on the floor or inverted. An endeffector, max. weight 7, 10 or 16 kg including payload, can be mounted on the robot’smounting flange (axis 6) depending on the robot version. See load diagrams onpage 11.Other equipment can be mounted on the upper arm, max. weight 11 or 12 kg, and onthe base, max. weight 35 kg. Holes for mounting extra equipment, see page 15.

The working range of axes 1-2 can be limited by mechanical stops and axis 3 by limitswitches. Position switches can be supplied on axis 1 for position indicator ofmanipulator.

Operating requirements

Protection standards IEC529

Standard Manipulator IP54

IRB 2400FL Manipulator IP55Wrist IP67Connectors IP67

IRB 2400F/10 and 16 Manipulator IP67

Explosive environments

The robot must not be located or operated in an explosive environment.

Ambient temperatureManipulator 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 humidityComplete robot during transportation and storage Max. 95% at constant temperatureComplete robot during operation Max. 95% at constant temperature



Description

Mounting the manipulator

Maximum load in relation to the base coordinate system.

Endurance load Max. load at

in operation emergency stopIRB 2400L Force xy ±1700 N ±2100 N

Force z floor mounting +4100 ±1100 N +4100 ±1400 NForce z inverted mounting -4100 ±1100 N -4100 ±1400 N

Torque xy ±3000 Nm ±3400 NmTorque z ±450 Nm ±900 Nm

IRB 2400/10 Force xy ±2000 N ±2600 NIRB 2400/16 Force z floor mounting +4100 ±1400 N +4100 ±1900 N

Force z inverted mounting -4100 ±1400 N -4100 ±1900 N

Torque xy ±3400 Nm ±4000 Nm

Torque z ±550 Nm ±900 Nm

Figure 4 Hole configuration (dimensions in mm).

0.25D=35

48

A

Z

2 8 0

D=18,5 (2x)

H8 (2x)+0.039-0

20

A - A

A

260

2 1 0

X

Y

View from the bottom of the base

Z = centre line axis 1

The same

260

B

B48

D=18,5

B - B

0.5

dimensions



Description

Load diagrams

Figure 5 Maximum weight permitted for load mounting on the mounting flange at different positions(centre of gravity).

Z = see the above diagram and the coordinate system in Product Specification S4CplusL = distance in X-Y plane from Z-axis to the centre of gravity

J = maximum own moment of inertia on the total handling weight = ≤ 0.012 kgm2

100

200

300

400

500

600

100 200 300

Z (mm)

L (mm)40065

1 kg

1.5 kg

2 kg

3 kg

4 kg

5 kg

IRB 2400L Nominal performance



Description


100

200

300

400

500

600

100 200 300

Z (mm)

L (mm)40065

IRB 2400L Reduced performance

1 kg

1.5 kg

2 kg

3 kg

5 kg

6 kg7 kg

4 kg





Description


IRB 2400/10

200

200

Z (mm)

L (mm)

100 150

150

10010 kg

12 kg

6 kg

8 kg

50

85





Description


IRB 2400/16

200

200

Z (mm)

L (mm)

100 150

150

100

50

85



16 kg14 kg

12 kg

10 kg



Description

Mounting equipment

The robot is supplied with tapped holes on the upper arm and on the base for mountingextra equipment.

Figure 9 The shaded area indicates the permitted positions (centre of gravity) for any extra equipmentmounted in the holes (dimensions in mm).

IRB 2400L

M8 (2x)Depth 14

4 0 0

300

Max. 10kg

A A

D=50

150

Max. 35 kg total

150135

M8 (3x) R=92Depth 16

120o (3x)

B

B

B - B

38o

C - C

C

C

CL

400 470 D = 2 0 0

170

30

Max. 1kg

120o (3x)

38o

M8 (3x) R=77

Depth 16

A - A

67

D D

37

70 (2x)

62

37

D - D

Depth 9

M5 (2x)

The rear side of the manipulator



Description

Figure 10 The shaded area indicates the permitted positions (centre of gravity) for any extra equipmentmounted in the holes (dimensions in mm).

D=50150

Max. 35 kg total

B

B

C

CThe rear side of the manipulator

4 0 0

300

3 5

7 0

65 177

M8 (3x)Depth of thread 14

A A

M6 (2x)

110

2 5

IRB 2400/10

IRB 2400/16

100

200

300 450

D=240

Max. 2kg

A - A

M5 (2x)

22

43

Max. 10kg

78 90

120o (3x)

38o

M8 (3x) R=77

M8 (3x) R=92Depth 16

120o (3x)

Depth 16

B - B

38o

C - C



Description

Figure 11 The mechanical interface, mounting flange (dimensions in mm).

7

D = 3 1 , 5

D=6+0.012-0

M6 (6x)

6 0 o

3 0 o

A - A

A

A

R=25

0.05 B

D = 6 3

h 8

B

5 x

H7, depth min 8

H 8

4 5 o

D=6 H7

M6 (4x)

R=20

A

A

∅ 0.05 B

(4x)90o

IRB 2400L

IRB 2400/10

IRB 2400/16

6

D = 2 5

9

A - A

D = 5 0

h 8

B

H 8

+ 0 . 0

2 7

- 0

+ 0 - 0

. 0 3 9

+0.012-0

+ 0 . 0

3 9

- 0

+ 0 - 0

. 0 4 6

10



Description

1.4 Maintenance and Troubleshooting

The robot requires only a minimum of maintenance during operation. It has beendesigned to make it as easy to service as possible:

- Maintenance-free AC motors are used.

- Oil is used for the gear boxes.

- The cabling is routed for longevity, and in the unlikely event of a failure, itsmodular design makes it easy to change.

The following maintenance is required:

- Changing filter for the drive system cooling every year.

- Changing batteries every 3rd year.

- Changing oil in the wrist after the first year and then every 5th year.

The maintenance intervals depends on the use of the robot. For detailed information onmaintenance procedures, see Maintenance section in the Product Manual.



Description

1.5 Robot Motion

IRB 2400LThe working area is the same for both floor and inverted mounting

Type of motion Range of movement

Axis 1 Rotation motion +180o to -180o Axis 2 Arm motion +110o to -100o Axis 3 Arm motion +65o to -60o Axis 4 Wrist motion +185o to -185o Axis 5 Bend motion +115o to -115o Axis 6 Turn motion +400o to -400o (Unlimited as optional)

Fi 12 Th t iti f th b t (di i i )

Pos 4

Pos 5

Pos 6

Pos 2

Pos 1

Pos 3

R = 5 2 1

++

+

Axis 4

Axis 3

Axis 5 Axis 6

Axis 2

Axis 1

100

1810

pos. axis 2 axis 3

01234

56

000

110110

-100-100

0-6065

-6024.5

-6065

Angle (degrees)R = 5 7 0

R = 4

0 0

Pos 4

1702

3421

2885

560

Wrist centre

X

Z

pos. x

01234

56

Positions at wrist centre (mm)

z

16202298745

-246-403

6231088

+

Pos 0

+

970404602

1577400

-1611-115



Description

IRB 2400/10, IRB 2400/16The working area is the same for both floor and inverted mounting

Type of motion Range of movement

Axis 1 Rotation motion +180o

to -180o

Axis 2 Arm motion +110o to -100o Axis 3 Arm motion +65o to -60o Axis 4 Wrist motion +200o to -200o (Unlimited as optional)Axis 5 Bend motion +120o to -120o Axis 6 Turn motion +400o to -400o (Unlimited as optional)

Figure 13 The extreme positions of the robot arm (dimensions in mm).

Pos 4

Pos 5

Pos 6

Pos 2

Axis 3

Axis 5 Axis 6

Axis 2

Pos 3

+ + +

+

Axis 4

+

Wrist centre

R = 4 4 8

Pos 1

Axis 1

1441

100

1550

393

2458

2900

R = 5 7 0

R = 4 0 0

Pos 4

pos. axis 2 axis 3

0123456

0-6065

-6018.3-6065

Angle (degrees)

pos. x

0123456

Positions at wrist centre (mm)

z

14552041693-118-302624

1036

X

ZPos 0

855360541

1351400

-1350-53

000

110110

-100-100



Description

Performance according to ISO 9283

At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axesin motion.

Unidirectional pose repeatability:RP = 0.06 mm

Linear path accuracy:AT = 0.45 - 1.0 mm

Linear path repeatability:RT = 0.14 - 0.25 mm

Minimum positioning time, to within 0.2 mm of the position:0.2 - 0.35 sec. (on 35 mm linear path)

0.4 - 0.6 sec. (on 350 mm linear path)

The above values are the range of average test-results from a number of robots. Ifguaranteed values are required, please contact your nearest ABB Flexible AutomationCentre.

Velocity

Versions: IRB 2400L IRB 2400/10 IRB 2400/16

Axis no. 1 150o /s 150o /s 150o /s2 150o /s 150o /s 150o /s3 150o /s 150o /s 150o /s4 360o /s 360o /s 360o /s5 360o /s 360o /s 360o /s6 450o /s 450o /s 450o /s

There is a supervision to prevent overheating in applications with intensive andfrequent movements.

Resolution

Approx. 0.01o

on each axis.

1.6 Signals

For more information of air and signals for extra equipment to upper arm, seeApplication Interface in chapter 2 Specification of Variants and Options.



Description




2 Specification of Variants and Options

The different variants and options for the IRB 2400 are described below.

The same numbers are used here as in the Specification form. For controller options, seeProduct Specification S4Cplus, and for software options, see Product SpecificationRobotWare Options.

1 MANIPULATOR

VARIANTS

Standard Foundry(requires option 035) (requires option 036)

021 IRB 2400L IRB 2400FL022 IRB 2400/10 IRB 2400F/10023 IRB 2400/16 IRB 2400F/16

IRB 2400 Application Version - Handling capacity

Application: F Robot adapted for foundry environments.Degree of protection as in chapter 1.3.The manipulator is finished with a special coating.

Reach: Specifies the max. reach at the wrist centre.Handling capacity: Specifies the nominal handling capacity.

Manipulator colour

330 The manipulator is painted with ABB orange.

353 The manipulator is painted with ABB orange Foundry.

331- Colours according to RAL-codes. Not available for Foundry protection348

Protection

035 Standard

036 FoundryRobot 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.

APPLICATION INTERFACE

Air supply and signals for extra equipment to upper arm

For connection of extra equipment on the manipulator, there are cables integrated intothe manipulator’s cabling, one FCI UT07 14 12SH44N connector and oneFCI UT07 18 23SH44N connector on the rear part of the upper arm




(R1/4”) at the base and an outlet (R1/4”) on the upper arm.

Signals 23 50 V, 250 mAPower 10 250 V, 2 AAir 1 Max. 8 bar, inner hose diameter 8 mm

(Available for options 041 and 042)

041 Integrated hose and cables for connectionof extra equipment on the manipulator tothe rear part of the upper arm.

042 Hose and cables for connection of extraequipment are extended to the wrist onthe outside of the upper arm. Not possible

on IRB 2400L, option 021.

043 Integrated wire feed cablingControl signals:16 signals, 49 V, 500 mAConnector on upper arm housing: Burndy 23-pin UTG 618-23PNConnector on robot base: Burndy 23-pin socket UT001823SHTPower signals:12 signals, 300 V, 4 AConnector on upper arm housing: Burndy 12-pin socket UTG 614-12SNConnector on robot base: Burndy 12-pin UT001412PHT

Not possible on IRB 2400/10 and /16.

Connection to

056 ManipulatorThe signals are connected directly to the manipulator base to one 40-pins Hartingconnector.

057 CabinetThe signals are connected to 12-pole screwterminals, Phoenix MSTB 2.5/12-ST-5.08,

to the the controller.

Connection to cabinet (Cable lengths)

675 7m676 15m677 22m678 30m

If 43xIf 042

If 057




EQUIPMENT

691 Safety lampA 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.

058 DressingMounting of extra equipment, e.g. tool system on robot before delivery, ordered fromABB Flexible Automation/ Department U .

POSITION SWITCH

Switches indicating the position of axis 1.A design with two stationary or 1, 2 or 3 adjustable switches is available. The switches

are manufactured by Telemecanique or Burnstein, and of type forced disconnect.

Note The switches are not recommended to be used in severe environment with sand orchips.

Switches axis 1 (see Figure 14)

069 One switch

070 Two switches

071 Three switches

Figure 14 Connections of the switches

072 Two switches, axis 1, stationary (see Figure 15)The two switches divide the working area of axis 1 into two fixed working zones, approx. 175°each. Together with external safety arrangement, thisoption allows access to one working zone at the sametime as the robot is working in the other one.

Figure 15 Connections of the switches.

Connection to

075 ManipulatorConnection on the manipulator base with one FCI 23-pin connector.

076 CabinetConnection on the cabinet wall. Position switch cables are included.The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08

Cable lengths078 7m0 9 5

Controller

Controller

Controller

The firstswitch

The secondswitch

The thirdswitch

Controller




080 22m081 30m

WORKING RANGE LIMIT

To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted

061 Axis 1Two extra stops for restricting the working range.The stops can be mounted within the areafrom 50o to 140o. See Figure 16.

Figure 16

062 Axis 2Stop lugs for restricting the working range.Figure 17 illustrates the mounting positionsof the stops.

Figure 17

063 Axis 3Equipment for electrically restricting the working range in increments of 5o.

140o50

o

50o

140o

80o

50o

20o

40o

70o



Accessories

3 Accessories

There is a range of tools and equipment available, specially designed for the robot.

Basic software and software options for robot and PC

For more information, see Product Specification S4Cplus, and Product SpecificationRobotWare Options.

Robot Peripherals

- Track Motion

- Tool System

- Motor Units



Accessories



Index

4 Index

A

accessories 27air supply 23

C

cooling device 4

E

emergency stop 8

enabling device 7equipment

mounting 15permitted extra load 15

extra equipmentconnections 23

F

fire safety 8

H

hold-to-run control 8humidity 9

I

installation 9inverted robot 9

L

load 9, 10load diagrams 11

M

maintenance 18mechanical interface 17motion 19mounting

extra equipment 15robot 10

mounting flange 17

N

noise level 4O

operating requirements 9options 23overspeed protection 8

P

payload 9performance 21

position switch 25protection standards 9

R

range of movementworking space 19

reduced speed 7repeatability 21Robot Peripherals 27robot versions 4, 23

S

safeguarded space stop 8delayed 8

safety 7Safety lamp 8, 25service 18service position indicator 25signal connections 23space requirements 4standards 7structure 3suspended robot 9

T

temperature 9troubleshooting 18

V

variants 23



Index

W

weight 4working space

restricting 8, 9, 26



Product Specification RobotWare Options

3HAC 9218-1 / BaseWare OS 4.0







© ABB Robotics AB

Article number: 3HAC 9218-1Issue: BaseWare OS 4.0


Sweden




CONTENTSPage

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................................................................................................................ 313.4 SpotWare Plus......................................................................................................... 34

3.5 DispenseWare ........................................................................................................ 35

3.6 PaintWare................................................................................................................ 37

3.7 PalletWare............................................................................................................... 39

4 Index................................................................................................................................. 43








Introduction



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 errorhandling.

- 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 betransferred 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 serialchannel.

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 requiredto 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 bewritten to or read from files on a diskette or other type of mass storage/memory.


- Storing production statistics on a diskette or ramdisk. This information can thenbe read and processed by an ordinary PC.

- The robot’s production is controlled by a file. This file may have been createdin a PC, stored on a diskette, and read by the robot at a later time.



Advanced Functions

Fixed position output

The value of an output (digital, analog or a group of digitals) can be ordered to changeat a certain distance before or after a programmed position. The output will then changeat the same place every time, irrespective of the robot’s speed.

Consideration can also be given to time delays in the process equipment. By specifyingthis time delay (max. 500 ms), the output is set at the corresponding time before therobot 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.


- 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, anoutput is set that starts the press.

- Starting and finishing process equipment. When using this function, the startwill always occur at the same position irrespective of the speed. For gluing andsealing, 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 logicalconditions before setting the output that starts the press. A procedure whichtakes care of the complete press start operation is called at a position just outsidethe 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 errormessage “Outside working range”, both during program execution and when the robotis 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 theprogram.


- 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 insidethe home volume, i.e. the corresponding output is set.

- The volume is defining where peripheral equipment is located within the work-ing space of the robot.



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 intothe 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 andafter that enters only when the corresponding output from the other robot isreset.

Movements in interrupt routines and error handlers

This function makes it possible to temporarily interrupt a movement which is inprogress and then start a new movement which is independent of the first one. Therobot stores information about the original movement path which allows it to beresumed later.


- Cleaning the welding gun when a welding fault occurs. When a welding faultoccurs, there is normally a jump to the program’s error handler. The weldingmovement in progress can be stored and the robot is ordered to the cleaningposition so that the nozzle can be cleaned. The welding process can then berestarted, with the correct parameters, at the position where the welding faultoccurred. This is all automatic, without any need to call the operator. (Thisrequires 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’ssystem parameters using AND, OR and NOT. Functionality similar to that of a PLCcan be obtained in this way.

Example:

- Output 1 = Input 2 AND Output 5.- Input 3 = Output 7 OR NOT Output 8.


- 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=1and input 3=0.

Interrupts from analog input or output signals

An interrupt can be generated if an analog input (or output) signal falls within oroutside a specified interval



Advanced Functions

RAPID instructions and functions included in this option

Open Opens a file or serial channelClose Closes a file or serial channelWrite Writes to a character-based file or serial channelWriteBin Writes to a binary file or serial channelWriteStrBin Writes a string to a binary serial channelReadNum Reads a number from a file or serial channelReadStr Reads a string from a file or serial channelReadBin Reads from a binary file or serial channelRewind Rewind file positionWriteAnyBin Write data to a binary serial channel or fileReadAnyBin Read data from a binary serial channel or fileReadStrBin Read a string from a binary serial channel or fileClearIOBuff Clear input buffer of a serial channelWZBoxDef Define a box shaped world zone

WZCylDef Define a cylinder shaped world zoneWZLimSup Activate world zone limit supervisionWZSphDef Define a sphere shaped world zoneWZDOSet Activate world zone to set digital outputWZDisable Deactivate world zone supervisionWZEnable Activate world zone supervisionWZFree Erase world zone supervisionStorePath Stores the path when an interrupt or error occursRestoPath Restores the path after an interrupt/errorTriggC Position fix output/interrupt during circular movementTriggL Position fix output/interrupt during linear movementTriggJ Position fix output/interrupt during joint movementTriggIO Definition of trigger conditions for one outputTriggEquip Definition of trigger conditions for process equipment with

time delayTriggInt Definition of trigger conditions for an interruptMoveCSync Position fix procedure call during circular movementMoveLSync Position fix procedure call during linear movementMoveJSync Position fix procedure call during joint movementISignalAI Interrupts from analog input signalISignalAO Interrupts from analog output signal



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 turnswithout having to make any movements.


- When polishing, a large work area is sometimes needed on the robot axis 4 oraxis 6 in order to be able to carry out final polishing without stopping. Assumethat the axis has rotated 3 turns, for example. It can now be reset using this func-tion, without having to physically rotate it back again. Obviously this willreduce cycle times.

- When arc welding, the work object is often fitted to a rotating external axis. Ifthis axis is rotated more than one turn during welding, the cycle time can bereduced because it is not necessary to rotate the axis back between weldingcycles.

Coordinated motion with multi-axis manipulators

Coordinated motion with multi-axis manipulators or robot carriers (gantries) requiresthe Advanced Motion option. Note that simultaneous coordination with several singleaxis manipulators, e.g. track motion and workpiece manipulator, does not requireAdvanced Motion.

Note! There is a built-in general method for defining the geometry for a manipulatorcomprising two rotating axes (see User’s Guide, Calibration). For other types ofmanipulators/robot carriers, comprising up to six linear and/or rotating axes, a specialconfiguration 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 takeeffect immediately, also during movement between two positions. The path correctionsmust be entered from within the program. An interrupt or multitasking is thereforerequired to activate the correction during motion.


- A sensor is used to define the robot input for path correction during motion. Theinput can be defined via an analog input, a serial channel or similar. Multitask-ing or interrupts are used to read this information at specific intervals. Based on



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. Acontinuous movement with a specific speed can also be programmed.


- A robot is working with two different stations (external axes). First, a workobject located at station 1 is welded. When this operation is completed, station1 is moved to a position where it is easy to change the work object and at thesame time the robot welds the work object at station 2. Station 1 is moved inde-pendently of the robot’s movement, which simplifies programming and reducesthe cycle time.

- The work object is located on an external axis that rotates continuously at a con-stant 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 inorder to shorten the cycle time.

Friction Compensation

During low speed (10-100 mm/s) cutting of fine profiles, in particular small circles, afriction 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, requirescareful tuning of the friction level (see User’s Guide for tuning procedure). Note thateven 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 applyingFriction Compensation.

External Drive System

With Advanced Motion, the possibility to connect off-the-shelf standard drive systemsfor controlling external axes is available. This can be of interest, for example, when thepower 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 threeexternal 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.



Advanced Motion


IndReset Resetting the work area for an axisIndAMove Running an axis independently to an absolute positionIndDMove Running an axis independently for a specified distanceIndRMove Running an axis independently to a position within one

revolution, without taking into consideration the number of turnsthe axis had rotated earlier

IndCMove Running an axis continuously in independent modeIndInpos Checking whether or not an independent axis has reached the

programmed positionIndSpeed Checking whether or not an independent axis has reached the

programmed speedCorrCon Activating path correctionCorrWrite Changing path correctionCorrRead Read current path correction

CorrDiscon Deactivating path correctionCorrClear Removes all correction generators



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 untilthe robot is powered off, i.e. even when the main process has been stopped andin manual mode.

- They are programmed using standard RAPID instructions, except for motioninstructions.

- They can be programmed to carry out various activities in manual or automaticmode, 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.


- The robot is continuously monitoring certain signals even when the robot pro-gram 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, forexample, welding. By putting this operator dialogue into a background task, theoperator can specify input data for the next work cycle without having to stopthe robot.

- The robot is controlling a piece of external equipment in parallel with the nor-mal program execution.

Performance

When the various processes are programmed in the correct way, no performanceproblems will normally occur:

- When the priorities for the various processes are correctly set, the normal pro-gram execution of the robot will not be affected.

- Because monitoring is implemented via interrupts (instead of checking condi-tions at regular intervals), processor time is required only when something actu-

ally 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. Multitaskingis 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.



FactoryWare Interface

2.4 FactoryWare Interface

This option enables the robot system to communicate with a PC using RobComm 3.0or later versions (see FactoryWare). The FactoryWare Interface 3.2 serves as a run-time license for RobComm, i.e. the PC does not require any license protection whenexecuting a RobComm based application. However, when developing such anapplication, 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 licenseprotection in the PC (hardware lock and password for design and run-time, or onlypassword 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 DDEServer will require the hardware lock and password.

The Factory Ware Interface 3.2 includes the Robot Application Protocol (RAP), basedon MMS functionality. The Robot Application Protocol is used for computercommunication. 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 thefigure below.

RAP

RPC (Remote Procedure Call)

TCP/IP

SLIP

RS232/RS422

Standard protocolsEthernet



FactoryWare Interface


- Production is controlled from a superior computer. Information about the robotstatus is displayed by the computer. Program execution is started and stoppedfrom the computer, etc.

- Transferring programs and parameters between the robot and a PC. When manydifferent programs are used in the robot, the computer helps in keeping track ofthem and by doing back-ups.

- Programs can be transferred to the robot’s ramdisk at the same time as the robotexecutes its normal program. When execution of this program has finished, thenew program can be read very quickly from the ramdisk and program executioncan continue. In this way a large number of programs can be handled and therobot’s memory does not have to be so big.

RAPID instruction included in this option

SCWrite Sends a message to the computer (using RAP)



RAP Communication

2.5 RAP Communication

This option is required for all communication with a superior computer, where none ofthe FactoryWare products RobComm, RobView, or DDE Server, are used. It includesthe same functionality described for the option Factory Ware Interface.

It also works for the FactoryWare products. For RobView and DDE Server, there is nodifference from the FactoryWare Interface (except that the price is higher). ForRobComm, in this case a license protection requirement in the PC is added.

Note that both FactoryWare Interface and RAP Communication can be installedsimultaneously.



Ethernet Services

2.6 Ethernet Services

NFS

Information in mass storage, e.g. the hard disk in a PC, can be read directly from therobot using the NFS protocol. The robot control program can also be booted viaEthernet instead of using diskettes. This requires Ethernet hardware in the robot.

FTP

This option includes the same functionality as described for Ethernet Services NFSexept that the protocol used for remote mounted disc functionality is FTP.

The aspect of authorization differs between NFS and FTP.


- All programs for the robot are stored in the PC. When a new part is to be pro-duced, i.e. a new program is to be loaded, the program can be read directly fromthe hard disk of the PC. This is done by a manual command from the teach pen-dant or an instruction in the program. If the option RAP Communication or Fac-toryWare 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 theuser programs for all the robots are stored on the PC. A software update or aprogram backup can easily be executed from the PC.



Profibus DP

2.7 Profibus DP

With a Profibus-DP Master/Slave board (DSQC368) in the S4C controller it ispossible to connect many sets of in- and output I/O units via the serial Profibus-DPfield bus net, and all the Profibus-DP signals are handled and addressed in the sameway as any other distributed I/O signal.

The maximum number of I/O units that can be defined in the S4C system is describedin User’s Guide Baseware chapter I/O data specification. As I/O units counts all DP-slave units connected to the S4C DP-master, the DP-slave, simulated I/Ounits 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 theDSQC368 master bus. All I/O units must fulfil the DIN 19245 Part 3 ProfibusSpecification - DP and must be certified by PNO1.

1. Profibus Nutzer Organization



Interbus-S

2.8 Interbus-S

With an InterBus-S generation 4 Master/Slave board (DSQC344) in the S4C robot con-troller, it is possible to connect many sets of input/output modules via the serial Inter-Bus-S field bus net.

The robot controller handles and addresses the InterBus-S I/O signals in the same wayit 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 doc-uments from e.g. Phoenix Contact & Co.



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 difficultand time consuming. Operating a robot with inaccurate load parameters can have adetrimental 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 andpayload are handled separately.

The identification procedure consists of limited predefined movements of axes 3, 5 and6 during approximately three minutes. The starting point of the identification motionpattern 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 willcause the robot to stop quickly and thereafter back off to relieve forces between therobot and environment.

Tuning is normally not required, but the sensitivity can be changed from Rapid ormanually (the supervision can even be switched off completely). This may benecessary 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 theadvantages of no added stick-out and weight, no need for connection to the e-stopcircuit, 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 Changing the sensitivity of the collision detection oractivating/deactivating the function.

ParldRobValid Checking that identification is available for a specific robottype.

ParldPosValid Checking that the current position is OK for identification.LoadId Performing identification.MechUnitLoad Defenition of payload for external mechanical units.



ScreenViewer

2.10 ScreenViewer

This option adds a user window to display user defined screens with advanced displayfunctions. The user window can be displayed at any time, regardless of the executionstate 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 characterscan be ASCII and/or horizontal or vertical strokes (for underlining, separating orframing).

• 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.

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, functionkey pressed, field modified, ...). A list of user screen commands can be associated withany of these events, then when the event occurs, the command list will be executed.

| XT| ##| ##| ##

| ##| ##| ##| ##| ##

Program number: ###

SpotTim File View

Next Prev. (Copy) Valid

PHASESSQUEEZEPREHEATCOOLING

## HEATCOLDLASTCOLDPOSTHEATHOLD

Heat stepper: ###interpolated: ##

| START|

| ####|| ####||| ####

|

| END||| ####

|||| ####|

| Tolerance: ###%| Force: ###daN| Forge: ###daN|| Fire chck: ###

|| Err allow: ###%| Numb err: ###

| CURENT (A) |



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 exe-cute 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, dependingon the comparison result.

- Displaying a different screen.

Capacities

The user screens can be grouped in a screen package file under a specific name. Up to8 packages can be loaded at the same time.

A certain amount of memory (approx. 50 kbytes) is reserved for loading these screenpackages.

- The screen package to be displayed is selected using the far right hand menu“View” (which shows a list of the screen packages installed).



Conveyor Tracking

2.11 Conveyor Tracking

Conveyor Tracking (also called Line Tracking) is the function whereby the robotfollows a work object which is mounted on a moving conveyor. While tracking theconveyor, 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 necessaryfor 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 switchbetween tracking the one or the other.

- Up to 254 objects can reside in an object queue which can be manipulated byRAPID instructions.

- It is possible to define a start window in which an object must be before trackingcan start.

- A maximum tracking distance may be specified.

- If the robot is mounted on a parallel track motion, then the system can be con-figured such that the track will follow the conveyor and maintain the relativeposition 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 asseen 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 addedconveyor motion and they require accurate conveyor calibration.


WaitWObj Connects to a work object in the start windowDropWObj Disconnects from the current object



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 spotwelding 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 useother digital I/O units that conform with the DeviceNet specification.ABB Robotics AB does not assume any responsibility for the functionality or qualityof such units. The user must provide the appropriate configuration data.



Developer’s Function

2.13 Developer’s Function

This option is intended to be used by application developers requiring more advancedfunctions than normally available for an end user. The package includes a detailedreference manual on the RAPID language kernel and a number of instruction andfunction 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 concerningthe kernel, i.e. all general language elements which are not used to control robot orother 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 abyte. The instructions/functions are:

byte Data type for a byte data

BitSet Set a specified bit in a byte

BitClear Clear a specified bit in a byte

BitCheck Check if a specified bit in a byte is set

BitAnd Logical bitwise AND operation on byte

BitOr Logical bitwise OR operation on byte

BitXOr Logical bitwise XOR operation on byte

BitNeg Logical bitwise NEGATION operation on byte

BitLSh Logical bitwise LEFT SHIFT operation on byteBitRSh Logical bitwise RIGHT SHIFT operation on byte




Data Search Functions

With these functions it is possible to search all data in a RAPID program, where thename or the data type is given as a text string. This might be useful for instance in thefollowing examples:

- A common problem is to check if a data with a certain name is declared in thesystem, 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 declaredin 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 inapplication development.

User defined data types This will make it possible to create your own data types, likea record definition

AliasIO Instruction used to define a signal of any type with an alias(alternative) name. The instruction can be used to makegeneric modules work together with site specific I/O, with-out changing the program code.

ArgName Function used inside a routine to get the name of a dataobject, which is referenced as argument in the call of theroutine. The name is given as a string. The function can alsobe 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 definedtext 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 tochange the current active tool or workobject.

IsStopStateEvent Function which will return information about the movementof the Program Pointer (PP).




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 atpower on. The following instructions are included and are normally used in the poweron event routine:

PFIOResto Restore the values of all digital output signals.

PFDOVal Get the value of the specified digital output signal at the timefor power failure.

PFGOVal Get the value of the specified digital output group at the timefor power failure.

PFRestart Check if path has been interrupted.

Trigg Functions

TriggSpeed Instruction to define conditions and actions for control of ananalog output signal with an output value proportional to theactual TCP speed.

StepBwdPath Instruction used to move backward on its path in a RESTARTevent 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 onmass memory like floppy disc, flash disc or hard disc. It can be used when creatingapplication packages, using RAPID, where RAPID programs and modules should beloaded or stored. It can also be used to search for all files in different directories ande.g. list them on the teach pendant.

The following instructions and functions are available:

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 fileFileSize Get the size of a file



ArcWare

3 ProcessWare

3.1 ArcWare

ArcWare comprises a large number of dedicated arc welding functions, which make therobot well suited for arc welding. It is a simple yet powerful program since both thepositioning of the robot and the process control and monitoring are handled in one andthe same instruction.

I/O signals, timing sequences and weld error actions can be easily configured to meetthe 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 serialinterface is also available.

Advanced process control

Voltage, wire feed rate, and other process data can be controlled individually for eachweld or part of a weld. The process data can be changed at the start and finish of awelding 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. Thisprovides a way of testing the robot program without having the welding equipmentconnected.

Automatic weld retry

A function that can be configured to order one or more automatic weld retries after aprocess fault.

Weaving

The robot can implement a number of different weaving patterns up to 10 Hzdepending on robot type. These can be used to fill the weld properly and in the bestpossible way. Weaving movement can also be ordered at the start of the weld in orderto facilitate the initial striking of the arc.



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 whilstwelding is in progress. This makes trimming of the process much easier because theresult can be seen immediately on the current weld. This can be done in both manualand automatic mode.

Weld Guiding

Weld guiding can be implemented using a number of different types of sensors. Pleasecontact your nearest ABB Flexible Automation Centre for more information.

Interface signals

The following process signals are, if installed, handled automatically by ArcWare. Therobot can also support dedicated signals for workpiece manipulators and sensors.

Digital outputs Description

Power on/off Turns weld on or off Gas on/off Turns gas on or off Wire feed on/off Turns wire feed on or off Wire feed direction Feeds wire forward/backwardWeld error Weld error

Error information Digital outputs for error identificationWeld program number Parallel port for selection of program number, or

3-bit pulse port for selection of program number, orSerial CAN/Devicenet communication

Digital inputs Description

Arc OK Arc established; starts weld motionVoltage OK Weld voltage supervisionCurrent OK Weld current supervisionWater OK Water supply supervisionGas OK Gas supply supervision

Wire feed OK Wire supply supervisionManual wire feed Manual command for wire feedWeld inhibit Blocks the welding processWeave inhibit Blocks the weaving processStop process Stops/inhibits execution of arc welding instructionsWirestick error Wirestick supervisionSupervision inhibit Program execution without supervisionTorch collision Torch collision supervision

Analog outputs DescriptionVoltage Weld voltageWire feed Velocity of wire feedCurrent Weld currentVoltage adjustment Voltage synergic line amplificationC t dj t t C t i li lifi ti



ArcWare

Analog inputs (cont.) Description (cont.)

Voltage Weld voltage measurement for monitoring andsupervision

Current Weld current measurement for monitoring and

supervision


ArcL Arc welding with linear movementArcC Arc welding with circular movementArcKill Aborts the process and is intended to be used in error

handlersArcRefresh Updates the weld references to new values



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 correctionswill take effect immediately, also during movement between two positions. Thepath corrections must be entered from within the program. An interrupt or mul-titasking is therefore required to activate the correction during motion.


A sensor is used to define the robot input for path correction during motion. Theinput can be defined via an analog input, a serial channel or similar. Multitask-ing or interrupts are used to read this information at specific intervals. Based onthe input value, the path can then be adjusted.

- Adaptive process control.Adaptive process control for LaserTrak and Serial Weld Guide systems. Thetool provides the robot system with changes in the shape of the seam. These val-ues can be used to adapt the process parameters to the current shape.


CorrCon Activating path correctionCorrWrite Changing path correctionCorrRead Read current path correctionCorrDiscon Deactivating path correctionCorrClear Removes all correction generatorsSpcCon Activates statistical process supervisionSpcWrite Provides the controller with values for statistical process super-

visionSpcDump Dumps statistical process supervision data to a file or on a

serial channelSpcRead Reads statistical process supervision informationSpcDiscon Deactivates statistical process supervision



SpotWare

3.3 SpotWare

SpotWare comprises a large number of dedicated spot welding functions which makethe robot well suited for spot welding. It is a simple yet powerful program since boththe positioning of the robot and the process control and monitoring are handled in oneand 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 iscompleted. The robot’s self-optimising motion control, which results in fastacceleration and a quick approach to the spot weld, also contributes to making cycletimes shorter.

I/O signals, timing sequences and weld error actions can be easily configured to meetthe 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 ofguns, irrespective of the signal interface.

Adaptation to different weld timers

The robot can handle different types of weld timers. Normally communication with theweld timer uses parallel signals but a serial interface is also available for some types ofweld timers.

Continuous supervision of the welding equipment

If the option Multitasking is added, supervision can be implemented irrespective of thespotweld instruction. For example, it is possible to monitor peripheral equipment evenwhen program execution has been stopped.

Closing the gun

It is possible to start closing the spot welding gun before reaching the programmedpoint. By defining a time of closure, the gun can be closed correctly regardless of thespeed of the robot. The cycle time is optimised when the gun is just about to close atthe 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 toreach 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 userdefined input signal or a delay time after weld ready.



SpotWare

Immediate move after Move enable

The robot moves immediately when enable is given. This is achieved by preparing thenext action while waiting for the current weld to be completed.

Gun controlThe 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. Whenit 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 spotwelding gun. This makes the program easier to test.

Rewelds

A function that can be configured to order one or more automatic rewelds or, when theprogram 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-serviceposition, 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 implementedin a similar way as for program execution, i.e. with gun control and processsupervision. 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 Descriptionstart 1 start signal to the weld timer (tip 1)start 2 start signal to the weld timer (tip 2)

close tip 1 close gun (tip 1)close tip 2 close gun (tip 2)work select select work or retract stroke of the gunprogram parity weld program parity bitreset fault reset the weld timerprocess error operator request is set when an error occurscurrent enable weld inhibit to the weld timerp2 request set pressure 2p3 request set pressure 3p4 request set pressure 4weld power activate the weld power unit contactorwater start activate water coolingmanual close gun close gun manuallymanual open gun open gun manually

l l t t ld





SpotWare Plus

3.4 SpotWare Plus

In addition to the SpotWare functionality the robot can weld with up to four stationarywelding guns simultaneously.


SpotML Multiple spot welding with linear movement.



DispenseWare

3.5 DispenseWare

The DispenseWare package provides support for different types of dispensingprocesses such as gluing and sealing.

The DispenseWare application provides fast and accurate positioning combined with aflexible process control.

Communication with the dispensing equipment is carried out by means of digital andanalog outputs.

DispenseWare is a package that can be extensively customized. The intention is thatthe user adapts some user data and routines to suit a specific dispensing equipment andthe 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 - 5digital 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 signalsand 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 speedproportional 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 typesof dispensing equipment.

- Possibility to restart an interrupted dispense sequence.

Programming principles

Both the robot’s movement and the dispensing process control are embedded in theinstructions, DispL and DispC respectively.



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 Dataand 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 withthe given data

DispC Move the TCP along a circular path and perform dispensingwith the given data

Dispensing data

Data type Used to define:

beaddata Dispensing data for the different beads.

equipdata Dispensing data for the equipment in use.



PaintWare

3.6 PaintWare

PaintWare comprises a large number of dedicated painting functions which make therobot well suited for painting and coating operations. It is powerful, yet simple sinceboth the robot positioning and the paint events are handled in one and the sameinstruction. All phases of the paint process are controlled, such as start, change, andstop painting, due to trig plane events.

The necessary structures for paint process data are predefined and organised asBrushData 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 partbeing coated and the thickness requirements. These process parameters are changedalong 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 differentbrushes during a linear paint instruction. A brush can contain up to five parameters:

Paint The Paint/Fluid flow reference.Atom_air The Atomizing air reference.Fan_air The Shape air reference.

Voltage The Electrostatic voltage reference.Rotation The Rotation speed reference (for rotational applicators).

The five parameters may go directly to analog outputs controlling the spray gun in anopen 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 isselected 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 coordinatesystem. It also describes which brush to use when the path crosses the plane. Event datamay be included in all linear paint instructions as optional arguments. A maximum often events can be contained in one PaintL instruction.

Data types included in this option

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

number



PaintWare


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



PalletWare

3.7 PalletWare

General

The PalletWare package is a set of Rapid modules and user screens, which performbasic operations related to a palletizing or depalletizing process. These operationsinclude a number of services which can be called from a main program to perform pickand place operations for one or up to five palletizing tasks in parallel. For each suchtask a number of separate dynamic variables are used to describe and keep track of eachon-going pallet operation. The PalletWare package is intended to work with Rapidmodules generated from PalletWizard, a PC tool for off-line programming of palletcycles. 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 taskto 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 taskto 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 onthe 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 pickedfrom an in-feeder, or a stack layer, where the product, e.g. an empty pallet, is searchedand picked from a stack.

If several pallet cycles are run in parallel, then one complete pick-place cycle is alwaysfinished 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 forpallets, tier sheets or slip sheets. All such stations and stacks are defined as regardsposition, with an individual coordinate system (work object).

The palletizing robot is normally an IRB 6400 or IRB 640 but any robot type may beused. The tool to use may be a mechanical gripper or a tool with suction cups, possiblywith separate grip zones for multiple picking and placing. Several different tooldatamay be defined and used depending on the product dimensions and number ofproducts.





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 ofproduct: regular products, empty pallets. From here the product dimension maybe 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, tooldata, 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 includedin the PalletWare delivery, but which must be written by the system integrator forspecific installations. These are:

- The “main” module, including the main routine. In this routine all logic forworking with parallel and simultaneous pallet cycles must be coded by the sys-tem integrator, including code required for operator messages, error handlingand product changes.

- A system module holding different operator dialogues, which may be calledfrom the main routine in order to change or check pallet cycles or to handleerror situations.



PalletWare

Pallet Wizard

Pallet Wizard is a complete stand alone tool, which enables you to describe the fullpalletizing 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 palletizingcycles. 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 eachother: how products will be settled in the tool, where products will be picked or placedon 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 processdata and modules in a RAPID format in order for PalletWare to manage them.

System requirements for option PalletWare

- Option ScreenViewer.

- Option Advanced Functions.



Index

INDEX

4 Index

A

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

B

BaseWare 5BaseWare Options 3BaseWare OS 3

C

coating 37Collision Detection 19communication

robot and PC 13continuous movement 10Contour tracking 9Conveyor Tracking 22

coordinated motion 9cross-connection

locigal conditions 7

D

dataread and write 5, 13transfer 5

DispenseWare 35DP-slave 17

DSQC344 18

E

error handler movement 7External Drive System 10

F

fieldbuses 17file

read and write 5, 13

fixed positionoutput 6

procedure call 6Friction Compensation 10

I

independent movement 10input or output signals

interrupts 7InterBus-S 18interrupt routine movement 7interrupts

from analog input or output signals 7

L

Load Identification 19logical conditions

cross connections 7

O

outputin fixed position 6

P

painting 37PaintWare 37parallel processing 12PLC functionality 7printout 5ProcessWare 3, 27Profibus DP 17program

back-up 13transfer 13

R

readdata 5file 5

Reset the work area 9

S

serial channel 5spot welding 31

SpotWare 31SpotWare Plus 34



Index

T

transferdata 5, 13file 13program 13

W

World Zones 6write

data 5file 5



Safety

CONTENTSPage

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 .............................................. 51.7.2 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................................................................. 91.8 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





Safety

1 Safety

1.1 General

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

The information does not cover how to design, install and operate a complete system,nor does it cover all peripheral equipment, which can influence the safety of the totalsystem.

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

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

People who work with robots must be familiar with the operation and handling of theindustrial robot, described in applicable documents, e.g. Users’s Guide and ProductManual.

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

1.1.1 Introduction

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

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

In the Product Manual/ Installation, instructions are provided for connecting safetydevices 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 (manip-ulator or controller).



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 robotaxis actuators, stops all moving parts and removes power from other dangerousfunctions controlled by the robot.

Enabling device – ISO 11161, 3.4

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

Safety stop – ISO 10218 (EN 775), 6.4.3

When a safety stop circuit is provided, each robot must be delivered with thenecessary connections for the safeguards and interlocks associated with this circuit. Itis necessary to reset the power to the machine actuators before any robot motion canbe initiated. However, if only the power to the machine actuators is reset, this shouldnot suffice to initiate any operation.

Reduced speed – ISO 10218 (EN 775), 3.2.17

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

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

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

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

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

1.5 Safe Working Procedures

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

1.5.1 Normal operations

All normal operations in automatic mode must be executed from outside thesafeguarded space.



Safety

1.6 Programming, Testing and Servicing

The robot is extremely heavy and powerful, even at low speed. When entering into therobot’s safeguarded space, the applicable safety regulations of the country concernedmust 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 highspeed. Operators must also be aware of the fact that external signals can affect robotprograms 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 followingpoints must be observed:

- The operating mode selector on the controller must be in the manual modeposition to render the enabling device operative and to block operation froma computer link or remote control panel.

- The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the operat-ing mode selector is in position < 250 mm/s. This should be the normal posi-tion when entering the working space. The position 100% – full speed – mayonly 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 fromthe 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 assoon 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 whenentering through the safety gate to the robot’s working space so that no-oneelse 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 whichinteract with the robot computer and enable the MOTORS ON mode.

Each electrical safety chain consist of several switches connected in such a way thatall 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 toMOTORS OFF mode. MOTORS OFF mode means that drive power is removed fromthe robot’s motors and the brakes are applied.



Safety

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

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

The time limits for the central two channel cyclic supervisions of the safety controlchain 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 robotcontroller and on the teach pendant.

External emergency stop devices (buttons, etc.) can be connected to the safety chainby the user (see Product Manual/ Installation). They must be connected in accordancewith the applicable standards for emergency stop circuits.

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

Before switching to MOTORS ON mode again, establish the reason for the stopand rectify the fault.

&

&

Interlocking

EN RUN

Drive

UnitM

K1 K2

LIM1 LIM2 ES2ES1

GS1 GS2 AS2AS1

TPUEn1

TPUEn2

Man2Man1

Auto1 Auto2

K1 K2

+ +

Externalcontactors



Safety

1.8 Mode selection using the operating mode selector

The applicable safety requirements for using robots, laid down in accordance withISO/DIS 10218, are characterised by different modes, selected by means of controldevices and with clear-cut positions.

One automatic and two manual modes are available:

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 pendantand, if 100% is selected, using Hold-to-run control.

In automatic mode, the operating mode selector is switched to , and all safetyarrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc.,are active. No-one may enter the robot’s safeguarded space. All controls, such asemergency stops, the control panel and control cabinet, must be easily accessible fromoutside 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 deviceactivated.

The automatic mode safeguarded space stop (AS) function is not active in this mode.

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



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 deviceactivated.

For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing thebutton stops program execution.

Note! the 100% mode may only be used by trained personnel. The applicable lawsand regulations of the countries where the robot is used must always be observed.

1.8.3 Automatic operationAutomatic 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 remotecontrol device. These functions should be wired and interlocked in accordance withthe applicable safety instructions and the operator must always be outside thesafeguarded space.

1.8.4 Enabling deviceWhen the operating mode selector is in the MANUAL or MANUAL FULL SPEEDposition, the robot can be set to the MOTORS ON mode by depressing the enablingdevice on the teach pendant.

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

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

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



Safety

1.8.5 Hold-to-run control

This function is always active when the operating mode selector is in the MANUALFULL 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-runbutton on the teach pendant must be depressed in order to execute a program. Whenthe button is released, the axis (axes) movements stop and the robot remains in theMOTORS 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-to-run button is pressed. Releasing the button stops program execution and activating thebutton will start program execution again.

For FWD and BWD execution modes, the next instruction is run by releasing andactivating 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 activatingthe 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, theprogram execution will be continued by releasing and activating the Hold-to-runbutton.

When the enabling device on the teach pendant is released, the sequence describedabove 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 lightcurtains, light beams or sensitive mats. The GS is active regardless of the position ofthe operating mode selector.

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



Safety

1.8.7 Automatic Mode Safeguarded Stop (AS) connection

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

The AS is by-passed when the operating mode selector is in the MANUAL orMANUAL 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 inorder to create a sufficiently large safety zone. This will reduce the risk of damage tothe robot if it collides with external safety arrangements, such as barriers, etc.

Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or bymeans of electrical limit switches. If the working space is limited by means of stops orswitches, the corresponding software limitation parameters must also be changed. Ifnecessary, movement of the three wrist axes can also be limited by the computersoftware. Limitation of movement of the axes must be carried out by the user.

1.8.9 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 peripheralequipment.

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.



Safety

1.9 Safety Risks Related to End Effectors

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

1.9.2 Tools/workpieces

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

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

1.9.3 Pneumatic/hydraulic systems

Special safety regulations apply to pneumatic and hydraulic systems.

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

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

1.10 Risks during Operation Disturbances

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

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

The industrial robot is a flexible tool which can be used in many different industrial

applications. All work must be carried out professionally and in accordance withapplicable safety regulations. Care must be taken at all times.



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 partsduring service work. There is a serious risk of slipping because of the high temper-ature 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 ABBRobotics must be complied with. Special attention must be paid to the followingpoints:

- The supplier of the complete system must ensure that all circuits used in thesafety function are interlocked in accordance with the applicable standards forthat 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 beturned off outside the robot’s working space.

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

- Emergency stop buttons must be positioned in easily accessible places so thatthe robot can be stopped quickly.

- Safety zones, which have to be crossed before admittance, must be set up infront 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 areavailable for the installation in question.

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

Although troubleshooting may, on occasion, have to be carried out while the powersupply is turned on, the robot must be turned off (by setting the mains switch to OFF)when repairing faults, disconnecting electric leads and disconnecting or 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. Inaddition to the risk of being hit by moving robot parts, you run the risk ofbeing 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



Safety

1.12 The following standards are of interest when the robot is parts ofa cell

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 machin-ing process

- The external voltage connected to the control cabinet remains live even whenthe 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 Installa-tion, 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 processmay be damaged.

EN 294 Safety of machinery - Safety distance to prevent dangerzones being reached by the upper limbs.

EN 349 Safety of machinery - Minimum gaps to avoid crushing ofparts of the human body.

EN 811 Safety of machinery - Safety distance to prevent dangerzones being reached by the lower limbs.

Pr EN 999 Safety of machinery - The positioning of protective equip-ment in respect of approach speeds of the human body.

EN 1088 Safety of machinery - Inter locking device associated withguards principles for design and selection.



Safety

1.14 Emergency Release of Mechanical Arm

If an emergency situation occur where a person is trapped by the mechanical robotarm, 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 smallerrobots (1400 and 2400), but for the bigger ones it might not be possible without amechanical lifting device, like an overhead crane.

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

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

1.15 Limitation of Liability

The above information regarding safety must not be construed as a warranty byABB Robotics that the industrial robot will not cause injury or damage even if allsafety instructions have been complied with.

1.16 Related Information

Described in:

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



Wereserveallrightsinthisdocumentandinthe

i n f o r m a

t i o n c o n

t a i n e

d t h e r e

i n .

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u s e o r

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A B B R o

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No.of pag

TitlePrepared

Approved by,date

Responsible department

Take over department

K-G Ramström, 000119Declaration by the manuf.

Till k d kl ti

K-G Johnsson, 000110Technical Provisions

SEROP/KM

Product Design Responsible

Page

1

Status

Declaration by the manufacturer

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

Herewith we declare that the industrial robot

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

IRB 6400S IRB 6400PE IRB 6400R IRB 840

manufactured by ABB Robotics Products AB 721 68 Västerås, Sweden

with serial No.

Label withserial number

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

machinery covered by this directive and must not be put into service until the machinery intowhich it is to be incorporated has been declared in conformity with the provisions of the

directive, 91/368 EEC.

Applied harmonised standards in particular:

EN 292-1 Safety of machinery, basic terminology

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

EN 418 Safety of machinery, emergency stop equipment

EN 563 Safety of machinery, temperatures of surfaces

EN 614-1 Safety of machiney, ergonomic design principles

EN 775 Robot safety

EN 60204 Electrical equipment for industrial machines 1)prEN 574 Safety of machinery, two-hand control device

prEN 953 Safety of machinery, fixed / moveable guards

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

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

EN 55011 Class A Radiated emission enclosure

EN 55011 Class A Conducted emission AC Mains

EN 50082-2 EMC, Generic immunity standard. Part 2: Industrial environment

EN 61000-4-2 Electrostatic discharge immunity test

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

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

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

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

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.

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

O N L Y F O R

I N F O

R M A T I O N





ABB ROBOTICS PRODUCTS AB CONFIGURATION LIST

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

For RAC: RAC Ref no: Sales order no:

Tested and approved: Date Name

MANIPULATOR:

CONTROL SYSTEM:

ROBOT SYSTEM:

DateDelivery from factory:

Delivery to customer:

Acceptance by customer:

Customer information:

Customer:

Address:

OPTIONS/DOCUMENTATION

QTY OPTION/PARTNO REVISION DESCRIPTION

To the User

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

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





Fault Tracing Guide

CONTENTSPage

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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http://-/?-







Fault tracing guide

1.2 Diagnostics

The control system is supplied with diagnostic software to facilitate troubleshootingand to reduce downtime. Any errors detected by the diagnostics are displayed in plainlanguage 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 50messages 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 duringnormal operation and can be used to read or delete the logs. All system and errormessages available are listed in User’s Guide.

1.2.1 Start up sequence description

FAULT LED during start-up

System Start up

Event Duration SYSTEM FAULT LED TPU OTHER

t0 --- POWER ON --- --- ---

t0-t1 10 - 15s RUNNING

BIOS

Flashing RED Indicates

communi-

cation

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 Oper-

ating System

Will continue to

flash if no OS is

found or if the

Hard Drive is not

found.

Indicates

communi-

cation

down

t1-t2 10 - 15s Loading of

Operating

System,

Operating

system

checks HW

configuration

Solid RED Indicates

communi-

cation

down

t1 t2 t3

FLASHINGRED

SOLIDRED

FLASHINGGREEN

SOLIDGREEN

t0



Fault tracing guide

1.2.2 Intermittent errors

Unfortunately, intermittent errors sometimes occur and these can be difficult toremedy. This problem can occur anywhere in the robot and may be due to externalinterference, 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 tonote the status of all the LEDs, the messages on the teach pendant, the robot’sbehaviour, etc., each time that type of error occurs.It may be necessary to run quite a number of test programs in order to pinpoint theerror. These are run in loops, which should make the error occur more frequently.

If an intermittent error occurs periodically, check whether something in theenvironment in which the robot is working also changes periodically. For example, itmay be caused by electrical interference from a large electric plant which onlyoperates periodically. Intermittent errors can also be caused by considerabletemperature changes in the workshop, which occur for different reasons.

t2 --- OS is up,

starts to run

Robot appli-

cation (Sup-

plier

Application

Files)

Will continue

Solid RED if the

Robot application

does not start

Indicates

communi-

cation

down

t2-t3 30 - 60s The initialis-

ing software

starts to set

up the Robot

application

(Supplier

Application

Files)

Flashing GREEN Starts to

communi-

cate, but the

window

may be

empty for

up to 30 s

more

IO computer down loads

about 15s after t2.

First CAN indications

about 20s after t2.

Robot Specific Data

Files are loaded.

t3 --- The initialis-

ing 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 Entire system ready for

use

Event Duration SYSTEM FAULT LED TPU OTHER





Fault tracing guide

1.3 Computer System

1.3.1 Indication LEDs on the Various Units

1.4 Location of units in the cabinet

The computer system consists of the PCI backplane DSQC 501, the main computerDSQC 500, the I/O computer DSQC 522, and the axis computer DSQC 503. Inside thecomputer chassis there are also the computer power supply DSQC 505, the battery unitDSQC 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 andFAULT 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: Maincomputer DSQC 500

IRB 1400 2400 4400 6400 640 840/A 340

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 3, 5 3, 5

Transformer

D C

l i n k

D r i v e u n i t 3

D r i v e u n i t 2

D r i v e u n i t 1

Supplyunit

C

o m p u t e r

s y s t e m



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 sup-

ply cables.

HDD IOE bus activityLED

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).



Fault tracing guide

It is also possible to connect a terminal on the COM1 serial port to check error log mes-sage.

COM2 RS232 On computer chassis.

Technical data

See Product Specification for controller S4Cplus.

COM1 RS232 Cabinet front (behind service hatch)

For temporary use, e.g. connection of Laptop/PC.

Technical data


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


RX 2 Receive Data

TX 3 Transmit Data

GND 5 Signal ground



Fault tracing guide

1.4.1 Signal description, RS 232 and RS 422

RS 232

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

Note! Only full duplex is supported.

Signal Explanation

TXD Transmit Data

RXD Receive Data

DSR Data Set Ready

DTR Data Terminal Ready

CTS Clear To Send

RTS Request To Send

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

Start bit (“0”)

Stop bit (“1”)

f=9600/19200 baudByte 1 Byte 2

10 V

0 V





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. Itsstatus 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 andcomputer system fans.

LED indications for DSQC 509

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

1.5.1 Status of the Panel unit, inputs, and outputs, displayed on the teach pen-dant

- 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 Panelunit, where outputs are marked with and inputs with

See the table below.

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

AS2AS1GS1ES2ES1 GS2NSMSEN

WARNING!REMOVE JUMPERS BEFORE CONNECTING

ANY EXTERNAL EQUIPMENT

Status LED’s



Fault tracing guide

Outputs DO

Inputs DI

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

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



Fault tracing guide

1.6 Distributed I/O

I/O units communicate with the I/O computer, located in the computer system, via theCAN 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 asfollows:

u Is I/O communication programmed in the current program?

u On the unit in question, the MS (Module status) and NS (Network status) LEDsmust be lit with a fixed green colour. See the table below regarding otherconditions. The panel unit is a unit on the CAN-bus, and the behaviour of the MCand NS described is true also for this unit.

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



Fault tracing guide

:

1.6.1 Digital and Combi I/O units

All the I/O units have the same LED indications. The figure below shows a digitalI/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.

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 com-

pleted

Flashing red Minor fault (recoverable) Restart device

Red Unrecoverable fault Replace device

OUTINNS

MS 16151413121110987654321 OUTIN

X1

X3

X2

X4

101101

101 101

Status LED’s

X5

112



Fault tracing guide

1.6.2 Analog I/O, DSQC 355

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 thateven 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.


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 con-

nections.

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.

+5VDC / +12VDC /

-12VDC 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 connec-

tors. If power is applied to unit but unit does not work, replace

the unit.

DSQC 355 ABB flexible Automation

N.U

MS

RS232 Rx

+5V

Bus status LED’s

CAN Rx

+12V

RS232 Tx

N.U

CAN Tx-12V

NS

Bus status LED’s

Analog I/O

X8

S3S2

X3X5

X2

X7



Fault tracing guide

1.6.3 Remote I/O DSQC 350, Allen Bradley


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.


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 opera-

tional.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

Bus status LED’s

DSQC 350 ABB Flexible Automation

POWER

NAC STATUS

CAN Tx

CAN Rx

NS

MS

X8

X9

X5

X3

C A N R x

N A C

S T A T U S

C A N T x

M S

N S

P O W E R



Fault tracing guide

1.6.4 Interbus-S, slave DSQC 351


POWER-24 VDC Green Indicates that a supply voltage is present, and has a

level above 12 VDC.


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 Inter-

bus-S network. If not as required, check parameter

setup.

BA Green Lit when Interbus-S is active. If no light, check net-

work, nodes and connections.

RC Green Lit when Interbus-S communication runs without

errors.

Bus status LED’s

D S Q C

3 5 1

A B B F l e x i b l e A u t o m a t i o n

POWER

CAN Tx

CAN Rx

NS

MS

POWER

RC

RBDA

BA

I n

t e r b u s - S

X3X5

X21X20

POWER

CAN TxMSNS

RC

POWER

RBDABA

CAN Rx



Fault tracing guide

1.6.5 Profibus-DP, DSQC352


Profibus active Green Lit when the node is communicating with the master. If

no light, check system messages in robot and in Profibus

net.


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 con-

nector. If not, check cables and connectors. If power is

available at the unit but the unit does not function,

replace the unit

Profibus active

Power

NS

MS

CAN Rx

CAN Tx

Bus status LED’s

D S Q C

3 5 2


CAN Tx

MS

POWERCAN Rx

PROFIBUS ACTIVE

X20

X5 X3

P r o f

i b u s

NS



Fault tracing guide

1.6.6 Encoder interface unit, DSQC354

1.6.7 Status LEDs description

Each of the units connected to the CAN bus includes 2 or 4 LED indicators which


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 connec-

tors, short circuit or broken wire.Internal error in unit. Con-

stant light indicates constant high level on input and viceversa. 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.

POWER

NS

MS

CAN Rx

CAN Tx

Status LED’s

D S Q C

3 5 4

A B B F l e x

i b l e A u

t o m a

t i o n

ENC 1A

ENC 1B

DIGIN 1

X20

X5 X3

E n c o d e r

Digin 1

CAN Tx

MSNS

POWER

CAN Rx

Enc 2AEnc 2BDigin 2

Enc 1AEnc 1B



Fault tracing guide

indicate the condition (health) of the unit and the function of the networkcommunication. 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 thedevice has power and is operating properly. The LED is controlled by software. Thetable below shows the different states of the MS LED.

Description Remedy / Source of fault

Off No power applied to thedevice.

Check power supply.

Green Device is operating in anormal condition.

If no light, check other LEDmodes.

Flashing green Device needs

commissioning due toconfiguration missing,incomplete or incorrect.The device may be in theStand-by state.

Check system parameters.

Check messages.

Flashing red Recoverable minor fault. Check messages.

Red The device has anunrecoverable fault.

Device may need replacing.

Flashing red/green The device is running

self test.

If flashing for more than a few

seconds, check hardware.



Fault tracing guide

NS - Network status

The bicolour (green/red) LED indicates the status of the communication link. TheLED is controlled by software. The table below shows the different states of the NSLED.

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.


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 mod-

ule.

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 con-

nections 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 net-

work are operative.

Check parameter to see if mod-

ule 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 con-

nections.

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.



Fault tracing guide

CAN Tx - CAN network transmit

CAN Rx - CAN network receive

u Check that the current I/O signal has the desired status using the I/O menu on theteach pendant display.

u Check the I/O unit’s LED for the current input or output. If the output LED is notlit, 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.

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 widthsthat are incorrectly set. If there is a problem, check the cables and the connectedequipment before doing anything else.

The communication can be tested using the integral test program, after strapping theinput to the output. See chapter 9.


Green LED. Physically connected to theCan Tx line. Flashes when the CPU isreceiving data on the CAN bus.

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


Green LED. Physically connected to the

Can Rx line. Flashes when the CPU istransmitting data on the Can bus.

If no light, check network and

connections.

NS LED is: To indicate Action

Off Not powered/not on-line

Flashing green On-line, not connected Wait for connection

Green On-line, connections established

Red Critical link failure, incapable of

communicating (duplicate MAC

ID, or bus-off)

Change MAC ID and/or

check CAN connection/

cables



Fault tracing guide

1.8 Drive System and Motors

The drive system, which consists of rectifier, drive unit, and motor, is controlled by theaxis computer.

.

Figure 3 A schematic description of the drive system.

The drive system is equipped with internal error supervision. An error is sent on viathe 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. Internaltroubleshooting cannot be performed in the operating environment.

1.9 Teach PendantThe teach pendant communicates with the I/O computer via a cable. This cable is alsoused 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 nothelp, check the 24 V power supply.

Communication errors between the teach pendant and the I/O computer are indicatedby 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 serialmeasurement boards and resolvers. The serial measurement board is used to collectresolver 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. Communicationwith the axis computer takes place across a differential serial link (RS 422).

The measurement system contains information on the position of the axes and thisinformation is continuously updated during operation. If the resolver connections aredisconnected or if the battery goes dead after the robot has been stationary for a longperiod 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 thesynchronised position and then, using the teach pendant, setting the counters to zero. Ifyou try to start program execution without doing the above, the system will give an

Computer

DC link Drive Unit M R

Serial measurementboard

Torque referenceRotor position



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 beendisconnected. 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, resolvererrors, and measurement board interference. The latter type of error relates to the 7thaxis, which has its own measurement board. If it is positioned too close to a source ofinterference, 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 issupplied 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 therobot and check to see whether the error disappears. If the error is still present, thedisk drive will probably have to be replaced. However, check the ribbon cable first.

NB: Never use diskettes without a manufacturer’s mark. Unmarked, cheap diskettescan be of very poor quality.

If the disk drive is completely dead, check the supply voltage connection to the diskdrive to see that it is +5 V, before replacing the drive. It is accessible on a two pinconnector 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 theMOTORS ON state, on the transformer. There is also a automatic three-phase 10 Afuse that supplies the power supply unit. There are also two fuses for customer ACsupplies, 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 thereis no longer a risk of short-circuiting.

The panel unit has one PTC fuse to protect the motor on chains. An open fuse isindicated 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



Fault tracing guide

XT31 in the upper compartment of the controller.

The floppy disk drive power supply is protected with a resetable fuse inside thecomputer 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 fuseunnecessary.

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 typicalimplementation 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 uniqueaddress that may appear in the System logs.

Type 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 reg-

isters.

1. Reports current energy

level.

2. Reports own health.



Fault tracing guide

1.14 Power Supply units

DSQC 506


AC OK RED/GREEN 3 x 55V supply OK (start of ENABLE chain)

X1

X5

X2

X3

X6

X4





DecommissioningCONTENTS

Page

1 Decommissioning............................................................................................. 3

1.1 General...................................................................................................... 3

1.1.1 Manipulators .................................................................................... 31.1.2 Controller ......................................................................................... 4

1.2 Scrapping .................................................................................................. 4

1.2.1 General warning .............................................................................. 4

1.2.2 Oil and grease ................................................................................. 4

1.2.3 Parts requiring special treatment when scrapping........................... 4

1.3 IRB 4400 ................................................................................................... 5

1.4 IRB 6400 and IRB 640 .............................................................................. 5

1.4.1 Scraping Balancing cylinders .......................................................... 6



Decommissioning

CONTENTSPage



Decommissioning

1 Decommissioning

1.1 General

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

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



Decommissioning

1.1.2 Controller

1.2 Scrapping

The Counter-weight for 6400 and 640 contains lead and must therefore always berecycled.

1.2.1 General warning

Before removing any parts from the manipulator, study the dismantling instruc-tions for the component in question. Dismantling instructions can be found inunder Repairs.

1.2.2 Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via anauthorised person/contractor in accordance with local regulations. Do not dispose ofoil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration maybe 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. Oxy-gen 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 scrappingthe part in question. The types of robot on which there are such parts are listed belowtogether with a description of how they should be removed.

Material Examples of components

Copper Transformers, cables

Tin Cables

Alu-Zinc sheet-

ing

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



Decommissioning

1.3 IRB 4400

Balancing cylinder

The balancing cylinder contains 3 preloaded spiral springs (see Figure 1). Beforescrapping (melting down, or other form of destruction) the springs must be unloadedin a safe way.

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) Beforescrapping (melting down, or other form of destruction) the springs must be unloadedin a safe way, (see chapter Scraping Balancing cylinders on page 6).

There are different types of balancing cylinder with a preloading force between 4500-8000 N.

Free length of unloaded springs = is about 300 - 400 mm. besides the length of thebalancing cylinder.

Spiral spring

Free length of spiral spring:

L = 470 mm



Decommissioning

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 orscrapping 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 dutyshredder plant 2205”) or similar, scrapping mills are available at all bigger scrap-merchants.

Alternative ways

If scrapping mills are not available the balancing cylinders except 3HAA 0001-EZ canbe opened by means of a blowpipe acc. to the sketches (see Scraping Balancingcylinders on page 7).

It is most important that no closed rooms remains when the scrap is shipped to thesteel plant for recycling.

Part no. 3HAA 0001-US.Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered springso it will be possible to cut another hole (200 x 100 mm) in the inner mantelsurface, 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

Singel Spiral spring

Double Spiral spring



Decommissioning

Cut a hole (250 x 150 mm) in the mantel surface, and then cut all the uncoveredspring. Finally cut a hole (40 mm) in the piston rod (alt.A) or cut off the piston rodend (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 itcan not be opened by means of a blowpipe, besides, the aluminium must beseparated from steel before recycling, and that can only be done in a shredder or bythe manufacturer. see Figure 5.

Figure 3Scraping Balancing cylinders

ca. 250

ca. 200

Cut off Piston rod



Decommissioning


ca. 250

Hole in the Piston rodCut off Spiral spring

Alternative A

ca. 250

Cut off Spiral spring

Cut off Piston rod

Alternative B

Ca Ø 40mm



Decommissioning




Decommissioning



Description

CONTENTSPage

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 .................................................................................... 104.4 Limitation of velocity .................................................................................. 10

4.5 ENABLE .................................................................................................... 11

4.6 24 V supervision........................................................................................ 11

4.7 Monitoring.................................................................................................. 11

5 External Axes .................................................................................................... 13



Description

CONTENTSPage



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 fromthe main computer to the axis computer.

The axis computer receives position set values from the main computer and currentposition from the serial measurement board. The axis computer use this data inregulating algoritms and transmitts torque set value and position values to the drivesystem.

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 thefunctions required to create, execute and store a robot program. They also containfunctions for coordinating and regulating the axis movements. Figure 1 shows howthe 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.

http://struc.pdf/

http://struc.pdf/



Computer System Description

Figure 1 The interfaces of the computer system.

Ethernet Serial ports

Com 1, Com 2

USBFlash disk

Floppy diskdrive (Option)

Cooling fans

Main computer

SMBusBattery unit

Computer powersupply

Process powersupply

Axis computer

I/O computer

Optional board(0-5)

EthernetEnable 1

TPU

Panel unit

Test inputs

Drive system 1

Measurement system 2

Drive system 2

Enable 2

PCI bus

Measurement system 1

I/O units (Optional)

See Figure 2

See Figure 3

See Figure 3

See Figure 3

I/O units (Optional)

Gateway units

Field bus boards

Serial channels SIO1, SIO2

CAN

CAN



Description Servo System

2 Servo System

2.1 Principle function

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

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

- 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 andthen 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 theoptimal regulator parameters regarding the gravity, moment of inertia and interactionbetween 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 resolversignal and a known relationship between the resolver angle and rotor angle. The thirdphase 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 therectifier voltage, are amplified to the working voltage of the motors.

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

The following diagrams outline the system structure for AC operation as well as thefundamental structure of the drive unit





Description I/O System

3 I/O System

Communicates with other equipment using digital and analog input and output signals.

Figure 3Overview of the I/O system.

Floppy disk

Flash disk

ATA / EIDE

USB

RS 232Com2

Main Computer

I/O ComputerTPU

Ethernet

GeneralSerial ports

Gatewayunit

I/O unit (s)

Panel unit

Profibus DP

Interbus-S

ControlNet

RS 422

RS 232

SIO2

SIO1

Field bus Master/Slave boards

Safety Signals

I/O I/O I/O

16

16

CAN2

CAN1

PCI bus



I/O System Description



Description Safety System

4 Safety System

The robot’s safety system is based on a two-channel safety circuit that is continuouslymonitored. If an error is detected, the power supply to the motors is switched off and thebrakes engage. To return the robot to MOTORS ON mode, the two identical chains ofswitches must be closed. As long as these two chains differ, the robot will remain in theMOTORS OFF mode.

Figure 4 below illustrates an outline principal circuit with available customer contacts.

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 externalemergency 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 beconnected by the user. In any of the MANUAL modes, the enabling device on the teachpendant overrides the AUTO STOP.

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

The aim of these safeguarded stop functions is to make the area around the manipulatorsafe 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 motorcontactors drop out, and the robot is stopped by the brakes. If the safety circuit breaks, aninterrupt call is sent directly from the panel unit to the computer system to ensure that thecause of the interrupt is indicated.

When the robot is stopped by a limit switch, it can be moved from this position by

M

LS

ES

GS

TPU En

Auto Manual

&

Solid State Switch

Contactor

Drive units2nd chaininterlock

Operatingmode selector

LS = Limit switch

TPU En = Enabeling device

AS = Automatic mode safeguars space stop

GS = General mode safeguard space stop

ES = Emergency stop

EN 1 / 2 RUN

EN1/2 = Enable signals from I/O and axiscomputer respectively.



Safety System Description

jogging it with the joystick while pressing the MOTORS ON button. The MOTORSON button is monitored and may be depressed for a maximum of 30 seconds.

LEDs for ES, AS and GS are connected to the two safety circuits to enable quicklocation of the position where the safety chain is opened. The LEDs are located on the

upper part of the panel unit. Status indication is also available on the teach pendantdisplay.

4.2 MOTORS ON and MOTORS OFF modes

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

In AUTO mode, you can switch the robot back on by pressing the MOTORS ONbutton on the operator’s panel. If the circuit is OK, the computer system then closesthe Solid state switch to complete the circuit.

When switching to MANUAL, the mode changes to MOTORS OFF, at which stagethe computer system also opens the Solid state switch.

In any of the MANUAL modes, you can start operating again by pressing the enablingdevice on the teach pendant. If the circuit is OK, the computer system then closes theSolid state switch to complete the circuit. The function of the safety circuit can bedescribed 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 twocategories of safety stops, category 0 and category 1. A safety analysis will show ifcategory 0 or 1 is applicable, see below:

The category 0 stop is to be used when the power supply to the motors must beswitched off immediately, such as when a light curtain, used to protect against entryinto the work cell, is passed. This uncontrolled motion stop may require special restartroutines 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 protectagainst entry into the work cell. This controlled motion stop takes place within theprogrammed 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 MANUALREDUCED SPEED position. Then the robot’s maximum velocity is limited to 250



Description Safety System

mm/s.

4.5 ENABLE

ENABLE 1 and ENABLE 2 are signals to the panel unit from the I/O computer andaxis computer respectively.

ENABLE 1 is affected if any error occurs in the execution of the I/O computerprogram, and ENABLE 2 is affected if any error occurs in the execution of the axiscomputer 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 axiscomputer.

Likewise the I/O computer and the axis computer monitor the program execution ofthe main computer. If any computer detects an error it affect either one of theENABLE 1and ENABLE 2.

4.6 24 V supervision

If the 24 V supply to the safety circuits drops out, the MOTORS ON contactors willdrop 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 theexternal part of the safety circuits, including switches and operating contacts. Thehardware 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 computersystem to monitor the status. If an interrupt occurs in the circuit, the status can beread.

If any of the switch functions are incorrectly adjusted, causing only one of the chainsof operation to be interrupted, the computer system will detect this. By means ofhardware interlocking it is not possible to enter MOTORS ON without correcting thecause.



Safety System Description





External Axes Description



Installation and Commissioning

CONTENTSPage

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........................................................ 101.8 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........................................................................................... 172.1 Signal classes ........................................................................................... 17

2.2 Selecting cables ........................................................................................ 17

2.3 Interference elimination............................................................................. 18

2.4 Connection types....................................................................................... 19

2.5 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




CONTENTSPage

2.10.1 Delayed safeguarded space stop .................................................. 31

2.11 Available voltage ..................................................................................... 31

2.11.1 24 V I/O supply .............................................................................. 312.11.2 115/230 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 35053

2.15.2 Interbus-S, slave DSQC 351 ......................................................... 56

2.15.3 Profibus-DP, slave, DSQC352....................................................... 59

2.16 Communication ....................................................................................... 612.16.2 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..................................................................... 723.3 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



3.3.9 RobInstall preferences..................................................................... 81

3.3.10 BootImage ..................................................................................... 82

3.3.11 Start window .................................................................................. 823.3.12 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

3.4 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 ona 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

3.5 Query mode questions .............................................................................. 87

3.6 Calibration of the manipulator ................................................................... 88

3.7 How to use the disk, Manipulator Parameters........................................... 88

3.7.1 Robot delivered with software installed ........................................... 893.8 Saving the parameters .............................................................................. 89





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 regulationsand other instructions very carefully. These are found in separate sections in theUser’s Guide and Product manual.

The installation must be done by qualified installation personnel and should con-form to all national and local codes.

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

Operating conditions:Ambient temperature + 5°C to + 45°C (direct air cooling)

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

Relative humidity Max. 95% at constant temperature

Storage conditions:

If the equipment is not going to be installed straight away, it must be stored in a dryarea 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 therobot 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,



On-Site Installation Installation and Commissioning

(see Figure 1).

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

1.4 Amount of space required

A

A

A - A

If the controller is supplied withoutits top cover, lifting devices mustnot be used. A fork lift truck mustbe used instead.

Min. 60°






1.5 Bolting the cabinet

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

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 connectorand a Burndy connector (see Figure 3).

Figure 3Connections on the cabinet wall.

4 0 0

720

XS2

XS1

Motor cable XP1

Measurementcable XP2




1.7 Mains power connection

Before starting to connect the mains, make sure that the other end of the cable isdisconnected from the line voltage.

The power supply can be connected either inside the cabinet, or to a optional socket onthe left-hand side of the cabinet or the lower section of the front. The cable connector issupplied but not the cable. The mains supply cables and fuses should be dimensioned inaccordance 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. 10.20mm) through the gland (see Figure 4) located on the left cabinet wall.

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 theside 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 rightposition.

Tighten the cable gland.

Fasten the cover plate.

PE

Cable gland

Connector

XT 26




1.7.2 Connection via a power socket

You can also connect the mains supply via an optional wall socket of type3x32A, or4x32A or via an industrial Harting connector (DIN 41 640). See Figure 5.

Cable connectors are supplied (option 132 - 134).

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 dirtand 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 onthe 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 modeposition.

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

CEE connector DIN connector




:

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 takesapproximately 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 theteach 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 forthe first time, ensure that the power supply is connected for at least 36 hourscontinuously, in order to fully charge the batteries for the serial measurementboard. It takes approx. 4 hours to fully charge a computer system battery.

After having checked the above, verify that

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

each axis moves and is restricted as intended.

emergency stop and safety stop (where included) circuits and devices arefunctional.

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

the teach and playback facilities function correctly.

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




the safeguarding is in place.

at reduced speed, the robot operates properly and has the capability to handle theproduct or workpiece, and

in automatic (normal) operation, the robot operates properly and has the capabilityto 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 theteach pendant telling you that the revolution counters are not updated. When such amessage appears, the revolution counter of the manipulator must be updated using thecalibration 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 control-

ler 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 beeninterrupted

WARNING: Working inside the robot working range is dangerous.

Press the enabling device on the teach pendant and, using the joystick, move the robotmanually 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 arestored using the teach pendant, as follows:

Press the Misc. window key (see Figure 6).

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

Select Service in the dialog box shown on the display.

Press Enter .

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2




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

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. CounterUpdate. The window in Figure 8 appears.

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 markedwith an x).

IRB Not rev. counter update

File Edit View Calib

1(1)

Service Calibration

Unit Status

X 1 Not updated Rev. Counter


3 Calibrated

4 Calibrated



Incl All Cancel OK

1(6)

Rev. Counter Update!

IRB

To calibrate, include axes and press OK.

Axis Status




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

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 updatingcan 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 theinstructions displayed on the teach pendant. When the robot stops, switch toMOTORS 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, thesetting of the revolution counters must be repeated.

Cancel OK

Rev. Counter Update!

IRB

The Rev. Counter for all marked axes

will be update.

It cannot be undone.

OK to continue?

+

-




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.






Installation and Commissioning 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. Signalsfrom 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 localstandards and regulations concerning insulation and area must always be compliedwith.

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 forGateway (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. ABBarticle no. 3HAB 8277-1. The cable is shielded and has four conductors, two forelectronic 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 forconnections between DSQC 350 and the Allen-Bradley PLC bus.



Connecting Signals Installation and Commissioning

Interbus-S:

Cables according to Phönix specification, e.g. “Green type”, should be used forconnections between the DSQC 351 and external Interbus-S bus.

Profibus DP:

Cables according to Profibus DP specification should be used for connections betweenthe 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 controllerare neutralised. External relay coils, solenoids, and other units must be clamped in asimilar way. Figure 11 illustrates how this can be done.

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

Figure 11 Examples of clamping circuits to suppress voltage transients.

+24V DC +0V

+24V DC, or AC voltage +0V

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

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

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

R C




2.4 Connection types

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

2.5 Connections

Detailed information about connection locations and functions will be found inchapter 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 oneconnection.

Note! The cable shield must be connected to the cabinet wall using EMC connect-

ing 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, orsimilar. To prevent interference, ensure that such conductors are not connected at theother end of the cable (antenna effect). In environments with much interference,disconnected conductors should be grounded (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 customerorder) 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 whenconnecting the shield to the case.

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

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

disconnected conductors should be grounded (0 V) at both ends.When contact crimping industrial connectors, the following applies:

Designation

X(T) Screw terminal

XP Male (pin)

XS Sockets (female)




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 industrialconnectors.

When two conductors must be connected to the same pin or socket, both of them arecrimped into the same pin or socket. A maximum of two conductors may be crimpedinto the same pin or socket.

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

Operators panel

in separate cabinetExternal axes Safety signals

External conn. Device Net

Mains conn.

I/O connections

External axes inRobot cabinet

ApplicationInterface Manipulator cables

EquipmentPosition switchesconnection to cabinet




2.6 Connection to screw terminal

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

Locations of socket terminals are shown in Figure 13. See also circuit diagram, “View

of control cabinet”, for more details.

Signal identification Location Terminals

Safeguarded stop Panel unit X1 - X4

Digital I/O I/O unit X1 - X4

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

Relay I/O I/O unit X1 - X4

RIO I/O I/O unit X1, X2

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




Figure 13 Terminal locations.

Cabinet view from above

X9 (SIO2)

X7 (CAN 1.3) X8 (CAN 2)

X15 (CAN1.1)

X6 (CAN 1.2)

Computer system

Base Connector Unit

XP8

XT21 XP6

XP5 XP58

I/O Units (X4)

X 1 - X 4Safety Signals

X10 (SIO1)

XT 31(24V I/O)

(COM2)

Panel Unit

Manipulator connections

Connection toCustomer powerCustomer signals

Connection toPosition switches

115/230 VAC




2.7 The MOTORS ON / MOTORS OFF circuit

To set the robot to MOTORS ON mode, two identical chains of switches must beclosed. If any switch is open, the robot will switch to MOTORS OFF mode. As longas the two chains are not identical, the robot will remain in MOTORS OFF mode.Figure 14 shows an outline principle diagram of the available customer connections,AS, GS and ES

.

Figure 14 MOTORS ON /MOTORS OFF circuit.

M

LS

ES

GS

TPU En

Auto Manual

&

Solid State Switch

Contactor

Drive units2nd chaininterlock

Operating

mode selector

LS = Limit switch

TPU En = Enabling device

AS = Automatic mode safeguard space stop

GS = General mode safeguard space stop

ES = Emergency stop

24V

EN1/2 = Enable signals from I/O computer and

RUN = Run command from Main computer

EN 1 / 2 RUN

Axis computer respectively




2.7.1 Connection of safety chains

Figure 15 Diagram showing the two-channel safety chain.

Man1Auto1

Man2Auto2

X1:11

X3:10

X2:11

X4:10

X4:3

X3:3

X3:7 *

9

12

11

8

4

4

9

11

8

12

Ext LIM2

External contactors

Ext LIM1

GS1

AS1

TPU En1

ES1

Optoisol.

Optoisol.

& EN

RUN Inter-locking

K1

K2

K10 V

K2

M

Drive unit

AS2

GS2

ES2

TPU En2 &

24 V *

See 2.7.2

Optoisol.

Optoisol.

24 V

24 V

CONT1

CONT2

*)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 con-nected to 24 V and X3/X4:8,9 is connected to external 0 V

X1-X4 connection tables, see section 2.8.

24V

X4:7

0 V

+

+

-

-

0 V

0 V

+

+

-

-

X3:12X4:12

Technical data per chain

Limit switch:loadmax. V drop

300 mA1 V

External contactors: loadmax. V drop

10 mA4 V

GS/AS load at 24V 25 mA

GS/AS closed “1” > 18 V

GS/AS open “0” < 5 V

External supply of GS/AS max.+35VDCmin. -35VDC

Max. potential relative tothe cabinet earthing andother group of signals

300 V

Signal class Control sig-nals

See 2.7.2




2.7.2 Connection of ES1/ES2 on panel unit

t

Figure 16 Terminals for emergency circuits.

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 mA24 VDC L/R: 2 A24 VDC R load: 8 A

External supply of ES relays=

min. 22 V betweenterminals X1:9,8 andX2:9,8 respectively

Rated current per chain 40 mA

Max. potential relative to thecabinet earthing and othergroups of signals

300 V

External Internal

24V 24V0V 0V External TPU Cabinet

X1:10 X1:9

E-stop relay

X1:2

X1:1ES1 out

Supply from internal 24V (X1/X2:10)

and 0V (X1/X2:10) is displayed. When ext. sup-

ply, X1/X2:3 is connected to ext. 24V and X1/ X2:8 is connected to ext. 0V (dotted lines).

External Internal

0V 24V 0V 24V External TPU Cabinet

E-stop relay

ES2 out

X2:2

X2:1

X2:10

X2:7 X2:8

X2:9

X1:7 X1:824V

0V

X2:1

X2:8

X1:7

X1:8

RUN CHAIN

X2:6




2.7.3 Connection to Motor On/Off contactors

Figure 17 Terminals for customer use.

2.7.4 Connection to operating mode selector

Figure 18 Terminals customer use.

2.7.5 Connection to brake contactor

Figure 19 Terminal for customer use.

X3:2

X4:2

1

1

K2 (Motor On/Off 2)

K1 (Motor On/Off 1)Technical data

Max. voltage 48V DC

Max. current 4A

Max. potential rela-

tive to the cabinet

earthing and other

groups of signals

300V

Signal class Control

S1.1.x1

S1.1.x1

7

6

5

3

2

1100% (Option)

100% (Option)

MAN2

MAN1

Auto2

Auto1Technical data

Max. voltage 48V DC

Max. current 4A


tive to the cabinetearthing and other

groups of signals

300V


8

4

X4:5

6

K3 (Brake)Technical data

Max. voltage 48V DC

Max. current 4A


tive to the cabinet

earthing and other

groups of signals

300V





2.8 External customer connections

Customer connections on panel unit: X1- X4.

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

AS2AS1GS1ES2ES1 GS2NSMSEN

WARNING!REMOVE JUMPERS BEFORE CONNECTING

ANY EXTERNAL EQUIPMENT

X1

X2

X3

X4

Chain statusLED´s

1 2 4 53 6 7 8 9 10 1211

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

1 2 4 53 6 7 8 9 10 1211

= jumper







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


Ext. MON 1:A 1 Motor contactor 1Ext. 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






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 2AS2 - 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




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.

Figure 20 Diagram for using external safety relays.

K2

K1

X3:4

X3:3

X3:1

X3:2

X4:1

X4:2

X4:3

X4:4

0 V

CONT1

Ext MON 1

Ext MON 224 V

CONT2

24 V

0 V

Panel unit Relays with positive action

Safety relay

To otherequipment

ES out

AS GSAS GS

ES out

Externalsupply

Externalsupply

Robot 1 Robot 2

Safety gate

Cell ES

(only one channel displayed)




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 twocategories of safety stops, category 0 and category 1, see below:

The category 0 stop is used when, for safety analysis purposes, the power supply tothe motors must be switched off immediately, such as when a light curtain, used toprotect against entry into the work cell, is passed. This uncontrolled motion stop mayrequire 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 whengates are used to protect against entry into the work cell. This controlled motion stoptakes 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 safeguardedspace stop together with AS or GS. A delayed stop gives a smooth stop. The robotstops in the same way as a normal program stop with no deviation from theprogrammed path. After approx. 1 second the power supply to the motors is shut off.The function is activated by setting a parameter, see User’s Guide, section SystemParameters, 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 VRipple Max. 0.2 V

Permitted customer load Max. 7 ACurrent 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).




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 VPermitted customer load Max. 500 VAFuse 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 therobot has power on, for example.

- When there is a risk that major interference can be carried over into the inter-nal 24 V supply

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

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

Technical data:

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

Permitted supply voltage: I/O units 19 - 35 V including ripplepanel unit 20.6 - 30 V including ripple

Power Tap

A power tap connects the power supply to the trunk line. Power taps differ fromdevice taps in that they contain the following.

- A Shottky diode which connects to the power supply V+ and allows for mul-tiple supplies to be connected.

- Two fuses or circuit breakers to protect the bus from excess current whichcould damage the cable and connectors.






2.13.3 Connection and address keying of the CAN-bus

CAN 1.1 - 1.3.

Figure 21 Example of connection of the CAN-bus

X15 CAN1.1 (Internal I/O) No termination ofthe last unit

X7 CAN1.3

X6 CAN1.2

Base connector unit

I/O I/O I/O

I/O

I/O

I/O I/O

I/O

I/OSee Figure 22.

CAN bus

Control cabinet

1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

X15, X6, X7

Termination oflast unit

120 ohm, 1%0.25 W Metal film

1.2.3.4.5.




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

(see 2.6).u If CAN 1.2 is unused there should be a terminating resistor mounted in the X6

socket (exceptional case see below).

u If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit onthe CAN 1.2 chain.

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

u If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit onthe CAN 1.3 chain.

Note! If CAN 1.2, for example, is not connected in the end of any CAN chain butsomewhere between the end points of the chain, then no terminating resistorshould be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. theCAN chain should be terminated in both end points.

CAN 2

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 supplyunit.

I/OI/OI/O

Base connector unit

1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

X8 1. 0V_CAN2. CAN_L3. drain4. CAN_H5. 24V_I/O

See Figure 22.

1.2.3.4.5.

Termination oflast unit

120 W, 1%0.25 W Metal film

Controller

X8 CAN 2




Figure 22 CAN connections on base connector unit.

DeviceNet Connector

ID setting

Each I/O unit is given a unique address (ID). The connector contains address pins andcan be keyed as shown in Figure 23.

When all terminals are unconnected the highest address is obtained, i.e. 63. When allare connected to 0 V, the address is 0 (which will cause an error since address 0 is usedby the Panel unit). To avoid interference with other internal addresses, do not useaddresses 0-9.

X5

Input and ID Signal name Pin Description

V- 0V 1 Supply voltage GND

CAN_L 2 CAN signal low

DRAIN 3 ShieldCAN_H 4 CAN signal high

V+ 5 Supply voltage 24VDC

GND 6 Logic GND

MAC ID 0 7 Board ID bit 0 (LSB)

MAC ID 1 8 Board ID bit 1




MAC ID 5 12 Board ID bit 5 (MSB)

X15 CAN 1.1 (Internal I/O)

X6 CAN 1.2 (External I/O)

X7 CAN 1.3 (External I/O)

X8 CAN 2 (External I/O)

1

12




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. Allgroups are galvanically isolated and may be supplied from the cabinet 24 V I/Osupply or from a separate supply.

Technical data


Further information

For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.Circuit diagram, see chapter 11.

CONNECTION TABLE

X5 connec-tor

6 8 9 10 11 127

(0V)

address pins

address key

1 48

16322

Example:

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

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

1 2 3 4 5




Customer connections: X1 - X4

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

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

101101

101 101

Status LED’s

X5

112

CAN-connection, see 2.13.3

X1 X2

Unit function Signal name Pin Customer conn. Signal name Pin

Out ch 1 1 Out ch 9 1








0V for out 1-8 9 0V for out 9-16 9

24V for out 1-8 10* 24V for out 9-16 10*

Opto.

isol.

24V

0V




Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor con-nected to ground, to prevent disturbances, causes a short rush of current whensetting the input. When connecting outputs, sensitive to pre-oscillation current, aseries 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 digitaloutputs divided into two groups of 8. All groups are galvanically isolated and may besupplied from the cabinet 24 V I/O supply or from a separate supply.

The two analog outputs belong to a common group which is galvanically isolated

from the electronics of the controller. The supply to the two analog outputs isgenerated from24 V_CAN (with galvanically isolated DC/AC converter).

Technical data


Further information


CONNECTION TABLE

X3 X4


In ch 1 1 In ch 9 1

In ch 2 2 In ch 10 2







0V for in 1-8 9 0V for in 9-16 9

Not used 10 Not used 10

Opto.isol.

0 V

24 V




Customer connections: X1 - X4, X6

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

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

X2

X4

X6

1 10 101

1 6101 101

Status LED’s

X5

112


X1 X2










0V for out 1-8 9 0V for out 9-16 9

24V for out 1-8 10* 24V for out 9-16 10*

Opto.isol.

24V

0V




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

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

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

X3 X4


In ch 1 1 In ch 9 1








0V for in 1-8 9 0V for in 9-16 9


Opto.isol.

0 V

24 V




setting the input. When connecting outputs, sensitive to pre-oscillation current, aseries 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 functionssuch as controlling gluing equipment etc.

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

Technical data


Further information


CONNECTION TABLECustomer connections: X1, X3, X 5 - X8

Figure 24 Analog I/O unit

Connector X5- DeviceNet connectors

See section 2.13.3 on page 34.

DSQC 355 ABB flexible Automation

Bus status LED’s

Analog I/O

X8

S3S2

X3X5

X2

X7

X8-Analog inputs X7-Analog outputs

X5-DeviceNet inputand ID connector

Not to be used




Connector X7 - Analog outputs.

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

Signal name X7 Pin Description

ANOUT_ 1 Analog output 1, -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 23

GND 24

1

12

13

24




Connector X8 - Analog inputs

Signal name X8/Pin Description

ANIN_1 1 Analog input 1, -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 +24VDC supply

1 17

3216




Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor con-nected to ground, to prevent disturbances, causes a short rush of current whensetting the input. When connecting outputs, sensitive to pre-oscillation current, aseries 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 tosynchronise 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.








GND 25 Analog input 1, 0V




GND 29

GND 30

GND 31

GND 32

Signal name X8/Pin Description




Customer terminals:

Figure 25 Encoder unit, DSQC 354

Device Net connector X5, see section 2.13.3 on page 34

X5-DeviceNet input X3Not to be usedand ID connector

X20Conveyor connection

D S Q

C

3 5 4


X20

X5 X3

E n c o

d e r

Digin 1

CAN Tx

MSNSPOWER

CAN Rx

Enc 2AEnc 2BDigin 2

Enc 1AEnc 1B




Figure 26 Encoder connections.

The wiring diagram in Figure 26 shows how to connect the encoder and start signalswitch to the encoder unit. As can be seen from the illustration, the encoder issupplied with 24 VDC and 0V. The encoder output 2 channels, and the on-boardcomputer, use quadrature decoding (QDEC) to compute position and direction.

Connector X20 - Encoder and digital input connections

Encoder unit

12

3

4

5

6

7

8

9

1011

12

13

14

15

16

Opto

Opto

Opto

Opto

Opto

Opto

Galvanicinsulation

24 V I/O

0 V

Encoder

B

A

24 V DC

0 V

24 V DC

0 VSync switch

10-16 not to be used

or external supply




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 orfrom a separate supply.

Technical data


Further information


X20

Input and ID Signal name Pin Description

24 VDC 1 24 VDC supply

0 V 2 0 V

ENC 3 Encoder 24 VDC

ENC 4 Encoder 0 V

ENC_A 5 Encoder Phase A

ENC_B 6 Encoder Phase B

DIGIN 7 Synch switch 24 VDC

DIGIN 8 0V

DIGIN 9 Synch switch digital inputNot 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

1

16




CONNECTION TABLECustomer connections: X1 - X4

OUT

INNS

MS16151413121110987654321

OUT

IN

X1

X3

161

X2

X4

161

161 161

StatusLED’s

X5

112


X1 X2


Out ch 1a 1 Out ch 9a 1

Out ch 1b 2 Out ch 9b 2















supply




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

X3 X4


In ch 1 1 In ch 9 1








0V for in 1-8 9 0V for in 9-16 9








Opto.isol.

0 V

24 V




2.14 Digital 120 VAC I/O DSQC 320

Technical data


Further information


CONNECTION TABLECustomer connections: X1 - X4

OUT

INNSMS 16151413121110987654321 OUT

IN

X1

X3

161

X2

X4

161

161 161

Status

LED’s

X5

112

CAN connection, see 2.13.3




X1 X2Unit function Signal name Pin Customer conn. Signal name Pin

















isol.Opto

AC supply




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, twoconductor cable.

Technical data

See Allen-Bradley RIO specification.

Further information

X3 X4


In ch 1a 1 In ch 9a 1

In ch 1b 2 In ch 9b 2















isol.Opto AC

N





Customer terminals: X8 and X9

Figure 27 RIO-unit

When the robot is last in a RIO loop, the loop must be terminated with a terminationresistor according to Allen-Bradley’s specification.

Note! This product incorporates a communications link which is licensed underpatents and proprietary technology of Allen-Bradley Company, Inc. Allen-Brad-

ley Company, Inc. does not warrant or support this product. All warranty andsupport services for this product are the responsibility of and provided by ABBFlexible Automation.

RIO communication concept

X8 X9

Signal name Pin

Remote

I/O in

Signal name Pin

Remote

I/O outLINE1 (blue) 1 blue 1

LINE2 (clear) 2 clear 2

shield 3 shield 3

cabinet ground 4 cabinet ground 4


X5Device net inputand ID connector

Not to be used DSQC 350 ABB Flexible Automation

X8

X9

X5

X3

C A N R x

N A C S T A T U S

C A N T x

M S

N S

P O W E R

RIO in

RIO out




Figure 28 RIO communication concept - Principle diagram

The Allen Bradley system can communicate with up to 64 external systems. Each ofthese systems is called a Rack and is given a Rack Address 0-63. Basically, each robotconnected to the Allen Bradley system will occupy 1 rack.

Each rack is divided into 4 sections called Quarters. Each quarter provides 32 inputsand 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 thesame rack address, but different starting quarters must be specified.

The illustration above shows an example where Robot 1 uses a full rack while robot 2and robot 3 share 1 rack.

The rack address, starting quarter, and other required parameters such as baud rate,

Allen Bradleycontrol system

Robot 1 - 128 in / 128 out Robot 2 - 64 in / 64 out

128 in / 128 out

64 in / 64 out

Quarter 2

Quarter 3

Quarter 4

Quarter 1

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

Quarter 2

Quarter 1


Robot 3 - 64 in / 64 out

64 in / 64 out

Quarter 4

Quarter 3


Quarter 2

Quarter 3

Quarter 4

Quarter 1

Other systems




LED Status etc. are entered in the configuration parameters.

The robot may communicate with the Allen Bradley system only, or be used incombination with the I/O system in the robot. For example, the inputs to the robot maycome 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 theoutputs 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 musthave a external power feed so that the Interbus-S net would not shut down if a robotcell is turned off. The 24V power feed must come from outside the control cabinet andbe connected to the 2 pin Phoenix connector located on the Interbus-S card’s frontpanel marked 24V.

Technical data

See Interbus-S specification.

Further information


Unit ID to be entered in the Interbus-S master is 3. The length code depends on theselected data. Width between 1 and 4.




Customer terminals: see figure below regarding locations.

Figure 29 Interbus-S, DSQC 351

Communication concept

Figure 30 Outline diagram.

The Interbus-S system can communicate with a number of external devices, the actualnumber depends on the number of process words occupied of each unit. The robot canbe equipped with one or two DSQC 351. The Interbus-S inputs and outputs areaccessible 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 interconnectioncable 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).


X5-DeviceNet input X3Interbus-S supply

D S Q

C

3 5 1


I n t e r b u s - S

X3X5

X21X20

POWER

CAN TxMSNS

RC

POWER

RBDABA

CAN Rx

and ID connector

X21Interbus-Sout

X20Interbus-Sin

IN OUT IN OUT IN OUT

*1 *1

Robot 1Word 1.3

Robot 2Word 4.7

Robot 3Word 8.11

Master PLC.3 .7

1.11

2

64 in/64 out128 in/128 out




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

X20

Interbus-S IN Signal name Pin Description

TPDO1 1 Communication line TPDO1TPDI1 2 Communication line TPDI1

GND 3 Ground connection

NC 4 Not connected

NC 5 Not connected

TPDO1-N 6 Communication line TPDO1-N

TPDI1-N 7 Communication line TPDI1-N

NC 8 Not connected

NC 9 Not connected

X21

Interbus-S OUT Signal name Pin Description

TPDO2 1 Communication line TPDO2

TPDI2 2 Communication line TPDI2


NC 4 Not connected

+5V 5 +5VDC

TPDO2-N 6 Communication line TPDO2-N

TPDI2-N 7 Communication line TPDI2-N

NC 8 Not connected

RBST 9 Synchronisation

X3

Interbus-S supply Signal name Pin Description

0 V DC 1 External supply of Interbus-S

NC 2 Not connectedGND 3 Ground connection

NC 4 Not connected

+ 24 V DC 5 External supply of Interbus-S

5

1

9

6

1

59

6

1

5




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 cablethrough a special D-sub connector which works as a very short drop cable. Because ofthis 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: IOSignals. Circuit diagram, see chapter 17.

Customer connections

Figure 31 DSQC352, location of connectors

Communication concept

Figure 32 Profibus-DP communication concept

X20

Profibus

connection

X5 - DeviceNetconnector

X3 - Powerconnector

D S Q C

3 5 2


CAN Tx

MS

POWER

CAN Rx

PROFIBUS ACTIVE

X20

X5 X3

P r o f i b u s

NS

.3 .71

.112

128 in/128 out256 in/256 out

Robot 2Word 17:24

Robot 1Word 9:16

Robot 1Word 1:8

Master PLC

*1 *1




The Profibus-DP system can communicate with a number of external devices. Theactual number depends on the number of process words occupied of each unit. Therobot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputsare 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.

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

X20

Profibus-DP Signal name Pin Description

Shield 1 Cable screen

NC 2 Not connected

RxD/TxD-P 3 Receive/Transmit data PControl-P 4


+ 5V DC 6

NC 7 Not connected

Rxd/TxD-N 8 Receive/Transmit data N

NC 9 Not connected

X3

Profibus-DP supply Signal name Pin Description

0 V DC 1 External supply of Profibus-DP

NC 2 Not connected


NC 4 Not connected

+ 24 V DC 5 External supply of Profibus-DP

1

59

6

1

5




2.16 Communication

2.16.1 Serial links, SIO

The robot has three serial channels, which can be used by the customer tocommunicate with printers, terminals, computers, and other equipment(see Figure 33).

The serial channels are:

For permanent use.

- SIO1-RS 232 with RTS-CTS-control and support for XON/XOFF,

transmission speed 300 - 38 400 b/s.

- SIO2-RS 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.

Figure 33 Serial channels, SLIP, outline diagram.

External computer




Customer terminals, on base connector board:X10(SIO1) and X9(SIO2), see 2.6.

DSQC 504 (D-sub connectors)

Explanation of signals:

TXD=Transmit Data, RTS=Request To Send, RXD=Receive Data, CTS=Clear ToSend, DTR=Data Terminal Ready, DSR=Data Set Ready, DATA=Data Signals in HalfDuplex Mode, DCLK=Data Transmission Clock.

COM2 RS232 On computer chassis.

Technical data


X10 SIO1 X9 SIO2

Pin Signal Socket Signal

1 1 TXD

2 RXD 2 TXD N

3 TXD 3 RXD

4 DTR 4 RXD N

5 0 V 5 0 V

6 DSR 6 DATA

7 RTS N 7 DATA N

8 CTS N 8 DCLK

9 9 DCLK N


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

1

56

9

1

5 6

9




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


Figure 35 Connection behind service hatch.


RX 2 Receive Data

TX 3 Transmit Data

GND 5 Signal ground

External computer

External computer




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 IEEE802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The maincomputer board has no termination for a cable shield. The cable shield must begrounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net,connected via a HUB, see figure Figure 36.

Figure 36 Ethernet TCP/IP, Outline diagram.

2. I/O computer

is used for connection to a Laptop via outlet on cabinet front (behind service hatch) onthe controller see Figure 37.

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

Ethernet HUB

External Computer Controller Robot 1 Controller Robot 2 etc.

1

8




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.

Ethernet




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 protectionclass, IP 54, in accordance with IEC 144 and IEC 529.

Figure 38 Required preparation of external panel enclosure.

184

224180

140

193196

70

62

45o

External panel enclosure

(Option)

M8 (x4)

Connection to

Holes forflange

Holes foroperator’s panel

Holes forteach pendant holder

the controller

90

1555 (x2)

100%

Teach pendantconnection

200

240Required depth 200 mm

M4 (x4)

96

223








Installation and Commissioning Installing Program

3 Controller software

3.1 Introduction

If the robot controller is ordered with the software installed on delivery, the controllersoftware 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 toreconfigure 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 theCD-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.

Figure 39RobotWare CD-ROM installation.

Figure 40Controller Software installations.

RobotWare CD-ROM

To install RobInstall and

System Pack on PC

Install software

Ethernet:1. MC2. IOC

to install software

Create floppy disks

MC-EthernetNetwork in workshop

PCRobInstall

PCRobInstall

IOC-Ethernet with deliveredboot cable UTP-X

Floppy Disks Connected to IOC



Installing Program Installation and Commissioning

The transfer of the controller software to the controller flash disk from Ethernet orfloppy disks is executed by an elementary program named Boot Image.

This basic program must always be on the flash disk. At start-up, without anycontroller 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, thecontroller 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 activeagain.

3.1.1 RobotWare CD-ROM

To install:

Insert the CD in your reader and the install Shield starts automatically and guides youthrough 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 flashdisk. These actions are carried out in the same way as in a file manager or in WindowsExplorer.

Note! The CD contains all the System software and should therefore be treatedand 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 canbe used to install the manipulator parameters. In other cases, there is a label attachedto the manipulator on which clear instructions are given for manual loading of theparameters from the TPU.

Note! The disk is attached to the manipulator on delivery.




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 nameis an article number ending with the sub-number and with the revision number, forexample:

Media Pool directory

\3HAXaaaa-1.00 (RobotWare System Pack 3HAXaaaa-1,rev 00

\3HAXbbbb-1.02 (RobotWare System Pack 3HAXbbbb-1,

rev 02 \3HAXcccc-1.01 (ABB Robotics external option program3HAXcccc-1,

rev 01)

\3XYZdddd-1.00 (OEM customer external option program3XYZdddd-1,

rev 00)

(any program directory name is possible)

Figure 41MediaPool Directory.

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




3.2.2 System Pool in the PC

There must be one system home directory for each controller to be installed, forexample:

System Pool directory

Figure 42SystemPool Directory

The system home directory must hold two files to make installation of softwarepossible.

- 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 whichprepared *.cfg files can be preloaded and then included in the software installationprocedure.

Preparation of S4Cplus software to be installed

Figure 43Preparation of software.

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

Media pool System pool

System Pack in \3haxbbbb-1.nn

*.*signature no

Ext option in \3haxcccc-1.nn

*.*relkey.txt

Created filesMy system \system_n

key.idprogram.idkeystr.txt \syspar

*.cfg

Inserted key strings areSystem Pack fromRW release CD-ROM

External option fromdisk or CD-ROM

RobotWare key strings point out theSystem Pack they belong to and Ext Opt.key string points out added external optionprograms. All keys must have equal serial no.

key.idprogram.id

saved in keystr.txt




The latest revision of the System Pack and external option programs will be selectedas default.

When creating a new system to download to the controller via Ethernet or to transferto 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.idand the syspar directory.

This target file is temporarily stored in the system directory before download orcreating diskettes.

3.3 Installing new Software

Since most systems are already booted on delivery, the system CD-ROM need only beused 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 configurationin the following section.

3.3.1 Install cases

The first step is to install RobInstall on your PC. Then you can boot up your controllerin 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 controllerand PC/Laptop.

Make sure that the Network protocol is set for TCP/IP properties.


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.


Network Intranet connection DHCP

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




3.3.2 Ethernet set-up on PC

These settings must to be implemented to be able to achieve a connection between thePC and the I/O computer.

See the numeric value for IP Address, Subnet Mask, and Default Gateway in thefigure below.

Figure 44IP Address.

3.3.3 RobInstall

Robinstall is used to install the software in the robot control system. With Robinstallyou can start, pack, and download software for the S4Cplus robot system.

If you have not already installed RobInstall, please Insert the RobotWare CD-ROM inthe PC to be able to continue.

3.3.4 How to use RobInstallThe 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:

Click the start button on your PC and choose programs/ABB Robotics andRobInstall.




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-by-step instructions, see Figure 47.

2

1




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 newcontroller 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




image.


To load additional parameters, press Next, see Figure 50.

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.

Figure 51Change Option Configuration.

To change the Teach Pendant language, robot type, or software options, press

Options, see pos. 1.

1

1

2




If you want the system to boot up in query mode, put a mark in the query modeselection square. For further details of the query mode, see section 3.5.

Press Finish to create the controller image.


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.

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




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.




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.




Figure 58Select system.

RobInstall will now create an image file.

RobInstall will ask you to continue and also inform you how many diskettes theprogram 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, pressPreferences, see Figure 59.

To select a program package, press Select Media Pool, see Figure 60.




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, toload the system from boot disks, to set or check network settings, or to choose asystem 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 - Restart the system

Boot disks - Load the system from diskettes.

Network settings - Set network settings for main computer or check settings

for RobInstall. Select system - Choose a system from the hard disk drive.




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 - Restarts the system.

NO - Return to the start window.

3.3.13 BOOT DISKS

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

Figure 63Boot disks window.

OK - Check first that the correct diskette is inserted and that itis OK. The diskette is loaded or asked for again if loading isnot possible.

CANCEL - Removes all data loaded previously and returns to the startwindow.




3.3.14 NETWORK SETTINGS

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

Figure 64Network settings.

Main Computer - Show window with network settings for main computer.

I/O Computer - Show window with I/O computer and boot-pc settings.

CANCEL - Return to start window.

3.3.15 MAIN COMPUTER

This window will be displayed if the button MAIN COMPUTER was selected in theprevious window.

Note! The data in the window may not be correct. The exact data is enclosed withthe system.

Figure 65Main computer window.

MAC ID - MC: your ethernet address.

Current IP - Current IP address defined in the robot’s operating system.

IP - The address that will be defined at reboot.

Subnet mask - Only with FIX IP.

Gateway - Only with FIX IP. FIX IP - If the controller network uses a fixed IP address.




DHCP - If the network uses DHCP.

NONE - No IP address.

CANCEL - Return to the start window without changing settings.

OK - 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 theprevious 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 makeRobInstall work.

3.3.17 SELECT SYSTEM

The window shows all systems installed on the controller hard disk drive. Select bymoving 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.





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 methodcan be used:

Select the Service window .


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 startsthe Installation dialog.

Do not touch any key, joystick, enable device, or emergency stop during the coldstart until you are prompted to press any key.

3.4.3 X-start (Restart with the boot application and leaves the current systemon a local disk)

Select the Service window


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.




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. (Onlyvalid for robots within the same family).




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)




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 toboot up in [Silent], [Easy Query] or [Query] mode.

Silent

If Silent mode is selected, the system will boot up with the system configured inRobInstall.

Easy Query

If Easy Query is selected, it is possible to:




- 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.

For the IRB 6400R, you will also be asked which type of balancing units are used. Foridentification, 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 thecontroller (as in one of the two cases described below), a new parameter backupshould be saved on the disk, Controller Parameters.After saving the new parameters on the disk, Controller Parameters, the

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




Manipulator Parameters disk is no longer needed.

3.7.1 Robot delivered with software installedIn 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.






Maintenance and Repairs

CONTENTSPage

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........................................... 71.2.4 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...................................... 91.3.5 Check Flash disk capacity............................................................... 10

1.3.6 Changing Flash disk ........................................................................ 10

http://ser-main.pdf/












































Maintenance and Repairs

CONTENTSPage



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 preventativemaintenance must be carried out at specified periodic intervals, as shown in the tablebelow.

When handling units and other electronic equipment in the controller, the wriststrap in the controller must be used to avoid ESD damage.

u The control system is completely encased, which means that the electronics areprotected in a normal working environment. In very dusty environments, however,the interior of the cabinet should be inspected at regular intervals. Use a vacuumcleaner if necessary. Change filters in accordance with prescribed maintenanceprocedures.

u Check that the sealing joints and cable glands are really airtight so that dust and dirtare not sucked into the cabinet.

1.1 Maintenance Schedule

Prescribed maintenance Inspection Maintenance intervals

twice a

year

once a

year

4 000 h

or

2 years

12 000 h

or

3 years 5 years

20 000h

or

4 years

10 years

Filter for cabinet cooling. Xa

a. See 1.2 Changing filters/vacuum cleaning the cabinet cooling.

X

Computer System filter.

Battery Unit Xb

b. See 1.4 Changing the battery unit.

Cooling Fans X

Flash Disk Xc

c. See 1.5 Checking flash disk capacity.



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 ordetergent. The filter must not be wrung out, but should be allowed to dry on a flatsurface. Alternatively, the filter can be blown clean with compressed air from theclean-air side.

u If an Computer System filter is not used, the entire cooling duct must be vacuumcleaned regularly.

1.3 Changing filter on Computer cooling fan

With straight colling

To dismantle

u Place a screw driver in the track and turn the screw driver until the filter holdercome loose see Figure 1.

u Change filter.

Figure 1 changing filter.

To assemble

u Assemble in reverse order.



Maintenance-Repair Maintenance Schedule

1.4 Changing the battery Unit

1.4.1 With Straight Cooling

To dismantle

u 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.

Figure 2 Battery unit (Peltier Cooling).

u Pull the battery unit out carefully.

u Disconnect the connector and replace the unit.

To assemble


Computer Unit

Battery unit




1.4.2 With Peltier Cooling

To dismantle

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

Figure 3 Battery unit (Peltier Cooling).

u Pull the battery unit out carefully.

u Disconnect the connector and replace the unit.

To assemble


Computer Unit

Battery unit



Maintenance-Repair Maintenance Schedule

1.5 Changing Flash disk

To dismantle

u 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.

Figure 4 Transport locking.

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

Figure 5 Locking device.

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

Locking washer

Handles

Screw (turn two laps)

Handles

Lock




u 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 lowerleft side) on the metal bar.

Figure 6 Service position.

u Loosen the ten M5 srews and remove the cover from right side of the computer unitsee Figure 7.

u Loosen the M4 screw and pull out the Flash disk see Figure 7.

u Change the Flash disk.

Figure 7 Flash disk.

To assemble


Service position

Flash disk

M4 screw

M5 srew



Spare Parts ListCONTENTS

Page

1 Spare parts for S4Cplus ................................................................................... 2

1.1 Control System M2000.............................................................................. 2

1.1.1 Cabinet Set...................................................................................... 21.1.2 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



Spare Parts List

1 Spare parts for S4Cplus

1.1 Control System M2000

1.1.1 Cabinet Set

Cover control cubicle 1 3HAC 1526-1

Cover control cubicle 1 3HAC 0967-1

Locking device 3HAC 7137-1

Lock insert 1000-U5 Din 3mm 3 3HAB 2482-4

Lock insert EMKA/Daimler Benz 3 3HAB 2482-3

Lock insert 3524 2 3HAB 7219-2

Lock insert EMKA 3 3HAB 2482-1

Wingknob with locking cyl. 3524 1 3HAB 7862-2

1.1.2 Main Cable Set

Contactor 3 3HAB 2425-6

Resistor 2 3HAC 0977-1

Auxiliary contact 7 3HAB 5877-1

Auxiliary contact 3 3HAB 5878-1

1.1.3 Operators Panel

Cam switch 1 3HAC 2349-1

Emergency pushbutton 1 3HAB 5171-10

Lamp block 1 SK 616 003-A

Contact block 2 SK 616 001-A

Contact block (emergency) 1 3HAB 5171-1

Harness control panel 3-pos 3HAC 6428-1


Lamp block 1 SK 616 003-A

Contact block 2 SK 616 001-A

Contact block (emergency) 1 3HAB 5171-1

Actuator transparent 1 3HAB 7818-1


Cable harness control panel 1 3HAC 3132-1 opt.191

Cable harness control panel 1 3HAC 2355-1 opt.193

Protective ring 1 SK 615 512-1



Spare Parts List

Filament lamp 1 5911 069-10

Mains:

Circuit breaker 1 3HAC 2550-1

Fuse 3 3HAC 4803-1

1.1.4 Drive System 1400

Modules Drive System 1 3HAB 8101-6 DSQC 346B

Dummy Modul Drive System 1 3HAB 9271-1

Modules Drive System 1 3HAB 8101-8 DSQC 346G

Modules Drive System 1 3HAB 8101-1 DSQC 345A

Modules Drive System 1 3HAB 8101-12 DSQC 358E

Modules Drive System 1 3HAB 8101-3 DSQC 345BModules Drive System 1 3HAB 8101-10 DSCQ 358C

Fan Unit , 2 fans 1 3HAC 9174-1

Fan with receptacle 2 3HAC 6658-1

Int. cable fans 1-2 1 3HAC 8405-1

Fan Unit , 4 fans 1 3HAC 9173-1



Resistor Unit 1 3HAC 1616-4 1x47 ohm

Brake resistor 1 3HAB 9165-1

Bleeder internal conn. 1 3HAC 0759-1




Transformer Unit T1 1 3HAC 6161-1 200-440V






Mains line filter 1 3HAB 9628-1

Mains line filter 1 3HAC 7344-1 200-440V

Mains line filter 1 3HAB 9627-1 400-500V , 475-600V

C-jib Switch/Circ B Q1/F1 1 3HAB 7429-1



Spare Parts List







Modules Drive System 1 3HAB 8101-3 DSQC 345C


Fan Units , 2 fans 1 3HAC 9174-1











Bleeder internal conn. 1 3HAC 0759-1Transformer 3HAC 5601-1






Transformer Unit T2 3HAC 6160-1 475-600V

Main line filter 3HAC 6684-2

Main line filter 1 3HAB 9628-1

Main line filter 1 3HAC 7344-1 200-440V

Main line filter 1 3HAB 9627-1 400-500V , 475-600V




Spare Parts List




















Resistor Unit 1 3HAC 1616-1 4x47 ohmBrake resistor 4 3HAB 9165-1







Transformer Unit T2 3HAC 6160-1 475-600V

Main line filter 1 3HAB 9628-1

Main line filter 1 3HAC 7344-1 200-440V

Main line filter 1 3HAB 9627-1 400-500V , 475-600V




Spare Parts List





Modules Drive System 3HAB 8101-8 DSQC 346G


Modules Drive System 1 3HAB 8101-4 DSQC 345D

Fan unit , 4 fans 1 3HAC 9173-1


Int.cable fans 1-4 1 3HAC 8004-1

Resistor Unit 1 3HAC 1616-1
















Fan unit , 4 fans 1 3HAC 9173-1Fan with receptacle 4 3HAC 6658-1

Int.cable fans 1-4 1 3HAC 8004-1

Resistor Unit 1 3HAC 1616-1









Spare Parts List



1.1.9 Drive System 640, 840Modules Drive System 1 3HAB 8101-8 DSQC 346G







Mains line filter 1 3HAC 7344-1 200-400VMains line filter 1 3HAB 9627-1 400-500V , 475-600V



Modules Drive System 1 3HAB 8101-13 DSQC 346U



Modules Drive System 1 3HAB 8101-14 DSQC 345EModules Drive System 1 3HAB 8101-15 DSQC 358F










Spare Parts List

1.1.11 Drive System 6400PE

Electronic Time Relay 1 3HAB 7067-1

Mp-capacitor 1 4984 211-322 22nF 1000VDC/

500VACModules Drive System 1 3HAB 8101-8 DSQC 346G



Modules Drive System 3HAB 8101-3 DSQC 345C

Modules Drive System 3HAB 8101-4 DSQC 345D

Fan unit , 4 fans 3HAC 9173-1

Fan with receptacle 3HAC 6658-1

Int.cable fans 1-4 3HAC 8004-1Transformer Unit T3 1 3HAC 6164-1 200-440V






1.1.12 Drive System SetPower supply Bar 1 3HAB 8859-1

Bleeder external conn. 1 3HAC 0764-1

Ext.cable jib fans 1 3HAC8074-1

Drive system enclosure 1 3HAB 8820-1

Transformer cover 1 3HAC 4914-1

Maintenance stop 1 3HAC 6519-1

1.1.13 Connection SetHarness Drive system A1,A2 1 3HAC 5566-1

Cable jib Drive system 1 3HAC 5564-1

Harness Drive system A3 1 3HAC 6640-1

Harness Bas ext.ax.cab. 1 3HAC 7098-1

Filter unit ext. ax.cab. 1 3HAC 7272-1

Harness 1 external axis 1 3HAC 2779-1



Ext. axis in seperate Cabinet



Spare Parts List




Modules Drive System 1 3HAB 8101-8 DSQC 346GDummy Modul Drive System 1 3HAB 9271-1

Power supply Bar 1 3HAB 8859-1

Bleeder external conn. 1 3HAC 0764-1

Ext.cable jib fans 1 3HAB 7433-1

Harness Drive syst A1/A2 1 3HAB 9513-1

Cable jib Drive system 1 3HAB 7424-1

Int.cable external Drive Unit 1 3HAC 1919-1

Harness pow.ext.axes cab. 1 3HAC 2352-1

Harness pow.ext.axes cab. 1 3HAC 1821-1




Mains line filter 1 3HAC 7344-1

Mains line filter 1 3HAB 9627-1


Serial measurement board 1 3HAB 3700-1

Battery 1 4944 026-4

220V fan connection 1 3HAC 7687-1 opt.090

Electronic Time Relay 1 3HAB 7067-1

Mp-capacitor 1 4984 211-322 22nF 1000VDC/ 500VAC

1.1.14 Teach pendant

Prog.Unit w backlight 1 3HNE 00313-1

Prog.Unit cable 10m 2 3HNE 00188-1TPU plug 1 3HAC 4637-1

Extension Cable for TPU 1 3HNE 00133-1

Holder for for TPU 1 3HNM 00032-1

Guard/bracket 1 2188 0286-3

Distance 1 2153 0885-3

Cable Jib Teach Pendant 1 3HAC 6367-1

Multi pol.conn. 19p 1 3HAB 7290-19

Washer 3HAC 0199-1



Spare Parts List

1.1.15 Cables to manipulator

Control cable power 7m 1 3HAC 2492-1 340,1400, 2400

Control cable power 7m 1 3HAC 2512-1 640,840,4400,6400PE

Control cable power 15m 1 3HAC 2529-1 340,1400,2400






Control cable power 7m 1 3HAC 3382-1 Prot. Twisted 640,8404400,6400

Control cable power 15m 1 3HAC 3383-1 Pro. Twisted 640,8404400,6400

Control cable power 7m 1 3HAC 3386-1 Protection twisted1400,2400

Control cable power 15m 1 3HAC 3387-1 Protection twisted1400,2400

Control cable power 7m 1 3HAC 4417-1 6400R




Control cable power 7m 1 3HAC 5548-1 6400 metalbraided

Control cable power 15m 1 3HAC 5548-2 6400 metalbraided

Control cable power 7m 1 3HAC 8158-1 340 int.conn.




Control cable power 7m 1 3HAC 8182-1 Foundry IP684400,6400S




Control cable power 7m 1 3HAC 8184-1 Foundry IP68 6400R



Control cable power 30m 1 3HAC 8184-4 Foundry IP68 6400RControl cable power 7m 1 3HAC 9038-1 Foundry IP68 2400



Spare Parts List

Control cable power 15m 1 3HAC 9038-2 Foundry IP68 2400



Control cable signal 7m 1 3HAC 2493-1 640,840,1400,6400PEControl cable signal 7m 1 3HAC 2493-1 340,340r

Control cable signal 15m 1 3HAC 2530-1 640,840,1400,6400PE

Control cable signal 15m 1 3HAC 2530-1 340,340r





Control cable signal 7m 1 3HAC 3344-1 Prot.twisted 640,840

1400,2400,6400PE

Control cable signal 15m 1 3HAC 3345-1 Prot.twisted 640,8401400,2400,6400PE

Control cable signal 7m 1 3HAC 7998-1 2400,4400,6400,6400S






Drive System int.cable 1 3HAC 6326-1 140,340,1400,2400

Drive System int.cable 1 3HAC 6333-1 4400,6400PE,6400S

Drive System int.cable 1 3HAC 6340-1 640,84

Drive System int.cable 1 3HAC 6346-1 6400

Pos. switch cable 7m 1 3HAC 3363-1 1400




Pos. switch cable 7m 1 3HAC 3378-1 640,840,6400PE




Pos. switch cable 7m 1 3HAC 4948-1 6400 switch axes 2/3




Harness in cabinet 1 3HAC 7874-1





Spare Parts List

1.1.16 I/O Interfaces

CanBus cable I/O 1-2 1 3HAC 7501-1

CanBus cable I/O 1-4 1 3HAC 7416-1

I/O external connection 1 3HAC 7660-1

Dig. 24VDC I/O 1 3HAB 7229-1 DSQC 328

Harness Analog I/O 1 3HAC 6989-1

Analog I/O Unit, APIP-02 1 3HNE 00554-1 DSQC 355

Harness Combi I/O 1 3HAC 6993-1

A D Combi I/O 1 3HAB 7230-1 DSQC 327

Dig. 24VDC I/O 1 3HAB 7229-1 DSQC 328

Multipole con. X1-X4 10p. 1 3HAB 9715-1


Multipole con. X7, X8. 1 3HAB 7342-1

A D Combi I/O 3HAB 7230-1 DSQC 327


Multipole con.X6 6p. 1 3HAB 9664-1

Digital 120VAC I/O 3HAB 7231-1 DSQC 320

Multipole con. X1-X4 16p. 3HAB 9743-1

Digital with relays I/O 3HAB 9669-1 DSQC 332

Multipole con. X1-X4 16p. 3HAB 9743-1Ext.cust.conn.harness 1 3HAC 7043-1

Link customer connection 1 3HAC 6384-1

Circuit board RIO 1 3HNE 00025-1 DSQC 350

Multipole con.X8,X9 4p. 1 3HAC 0053-1

Interbus-S Unit 1 3HNE 00006-1 DSQC 351

Multipole con. X3 5p. 1 3HAC 1836-1

Profibus DP Slave unit 1 3HNE 00009-1 DSQC 352


ENC unit 3HAC 1701-1 DSQC 354

Can Bus internal 3HAC 7671-1

Can Bus cable 1 3HAC 7404-1

Male conn. with resistor. 2 3HAC 7954-1

Digital I/O Module 1 3HAB 7229-1 DSQC 328

Multipole con. I/O X5 1 3HAB 7178-1



Bridge connector 1 3HAB 8335-10



Spare Parts List

Metal film resistor 1 3HAC 0050-1



Multipole con. I/O X10 1 3HAB 7252-1Multipole con.set X7,X8 1 3HAB 7342-1



A D Combi I/O Module 1 3HAB 7230-1 DSQC 327




Multopole con. X6 6p. 1 3HAB 9664-1



Dig 120 VAC I/O Module 1 3HAB 7231-1 DSQC 320



Multipole con. X1-X4 16p. 3HAB 9743-1



Dig. with relays I/O Module 1 3HAB 9669-1 DSQC 332




Metal film resistor 3HAC 0050-1


Circuit board RIO 1 3HNE 00025-1 DSQC 350


Multipole con. I/O X10 1 3HAB 7252-1Multipole con. X6,X9 4p. 1 3HAC 0053-1



Interbus-S Unit 1 3HNE 00006-1 DSQC 351




Metal film resistor 1 3HAC 0050-1Multipole con. X3 5p. 1 3HAC 1836-1



Spare Parts List

Profibus DP Slave unit 1 3HNE 00009-1 DSQC 352



Bridge connector 1 3HAB 8335-10Metal film resistor 1 3HAC 0050-1


Circuit board ENC-01 1 3HNE 00065-1 DSQC 354





Termin. contact XS6 1 3HAC 7926-1

Termin. contact XS7 1 3HAC 7933-1

1.1.17 Computer system

Assembly Comp. Enclosure 1 3HAC 7148-1

Backplane 1 3HAC 3617-1 DSQC 501

Main computer 1 3HAC 3616-1 DSQC 500

Axis computer 1 3HAC 3619-1 DSQC 503

I/O computer 1 3HAC 8848-1 DSQC 522

Axis computer 1 3HAC 3619-1 DSQC 503

Card Bracket PCI 5 3HAC 5475-1

PC-harness 1 3HAC 6375-1

Power Supply Comp. 1 3HAC 4296-1 DSQC 505

Battery Unit 1 3HAC 5393-2 DSQC 508

Flash disc 64MB 1 3HAC 7927-1 DSQC 518

Flash disc 128MB 1 3HAC 7927-5 DSQC 518

Bracket 1 3HAC 7520-1 DSQC 507

Flash Adapter 1 3HAC 7055-1 DSQC 517

Straight cooling 1 3HAC 7155-1 opt.472

IP Protection, Fan 1 3HAC 6328-1

Fan Net 1 3HAC 6320-1

Cable jib. Power Sup.B.P 1 3HAC 6378-1

Harddisc harness 1 3HAC 6378-1

Fan with recptacle 1 3HAC 6658-1

Grating 1 2158 0132-176

Fan Unit 1 3HAC 6655-1Fan with receptacle 1 3HAC 6658-1



Spare Parts List

Fan holder 1 3HAC 5220-1

Grating 1 2158 0132-176

Cable jib. Ext.comp.fans 1 3HAC 6168-1

1.1.18 Computer communication

Disc drive unit 1 3HAC 6232-1

Floppy disc drive 1 3HAB 2480-1

Floppy signal/supply cable 1 3HAC 6157-1

Inner floppy bracket 1 3HAC 7255-1

Cover 1 3HAC 7273-1

Floppy cover 1 3HAC 8083-1

Floppy bracket 1 3HAC 7331-1Floppy cover 1 3HAC 7239-1

Shaft 1 3HAC 6717-1

Torsion spring 1 3HAC 7461-1

Lock washer 2 3HAA 3003-29

Gasket for floppy cover 1 3HAC 7433-1

Service set 1 3HAC 7855-1

Connector cover 1 3HAC 7290-1 opt.410

Outlet 2-p w. earth term. 1 3HAB 9621-4 opt.412

Outlet set 1 3HAC 8314-1 opt.411

Common outlet set 1 3HAC 8315-1 opt.411,412

Computer outlet 1 3HAC 7896-1

Power Supply Comp. 1 3HAC 7862-1

Base Conn Unit 1 3HAC 5689-1 DSQC 504

Bus cable DB44 1 3HAC 5498-1



Panel Unit 1 3HAC 5687-1 DSQC 509

Expansion set 1 3HAC 7518-1

Axis Conn Unit 1 3HAC 6546-1 DSQC 513


Expansion cable jib 1 3HAC 7419-1

1.1.19 Supply system

Power supply Proc 1 3HAC 4297-1 DSQC 506

Spring 1 3HAC 5319-1



Circuit Diagram

CONTENTSPage

1 Controller, diagram 3HAC 5582-2 Rev.0 .................................................................. 1-91





















































































































































































































































































































































































Installation and Commissioning Transporting and Unpacking

1 Transporting and Unpacking

NB:Before starting to unpack and install the robot, read the safety regulations andother instructions very carefully. These are found in separate sections in theUser’s Guide and Product manual.

The installation shall be made by qualified installation personnel and should con-form to all national and local codes.

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

Operating conditions:

Ambient temperature +5° to +50 ° 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 dryarea 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: 380 kg

Whenever the manipulator is transported, axis 2 must be bent backwards 30° and axis3 must be moved down to a position against the rubber stops on axis 2.

1.1 Stability / risk of tipping

When the manipulator is not fastened to the floor and standing still, the manipu-lator is not stable in the whole working area. When the arms are moved, care mustbe taken so that the centre of gravity is not displaced, as this could cause the

manipulator to tip over.

1.2 Parameter disk

The parameter disk is delivered with the manipulator in a box. and should be copied(in a PC) before they are used. Never work with the original diskettes. When you havemade copies, store the originals in a safe place.

Do not store diskettes inside the controller due to the high temperatures there.




Page




2 On-Site Installation

2.1 Lifting the manipulator

The best way to lift the manipulator is to use lifting straps and a traverse crane.Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 (see Fig-ure 1). The brakes must be manually released to make it possible to alter the posi-tions of the arms, see Chapter 2.7 Manually Releasing the brakes. The lifting strapdimensions must comply with the applicable standards for lifting. See also chapter2. 2 Turning the manipulator (inverted suspension application) .

Never walk under a suspended load.

Figure 1 Lifting the manipulator using a traverse crane.

Move the lower arm backwardsapprox. 14o to get balance.

Recommended lifting sling:Type: KDBK 7-8L=2 mLoad at 90o= 380 kg

14°




2. 2 Turning the manipulator (inverted suspension application)

A special tool is recommended when the manipulator is to be turned for invertedmounting (ABB article number 3HAB 8961-1).

When the special tool is mounted, the manipulator should be positioned according to

Figure 2. The manipulator is delivered in this position.

Figure 2 Manipulator with mounted turning tool.

Lifting beam

Fork lift

200 Nm200 Nm

min. 960

appr. 520

appr. R=1090

appr. R=1090

65o

135o

63 Nm

63 Nm




2. 3 Assembling the robot

2.3.1 Manipulator

The manipulator must be mounted on a level surface with the same hole layout as shown inFigure 3. The levelness requirement of the surface is as follows:

Use M16 (x3) screws to bolt the manipulator down (tightening torque 190 Nm, oiled screws).Two guide sleeves (art.no. 2151 0024-169) can be added to the rear bolt holes, to allow thesame robot to be re-mounted without program adjustment.

Figure 3 Bolting down the manipulator.

Note that washers must be used!

Suitable washers: D= 17 / 30 , T= 3 mm

When bolting a mounting plate or frame to a concrete floor, follow the generalinstructions for expansion-shell bolts. The screw joint must be able to withstand thestress loads defined in Chapter 2.5 Stress forces .

2.4 Suspended mounting

The method for mounting the manipulator in a suspended position is basically the same

0.5

0.25D=35

48

A

Z

2 8 0

D=18,5 (2x)

H8 (2X)+0.039-0

20

Section A - A

A

260

2 1 0

D=18,5

X

Y

View from the bottom of the base (footprint)

Z = centre line axis 1

The same dimensions

260




as for floor mounting.

Figure 4 Conversion of robot from floor-mounted to suspended configuration.

With inverted installation, make sure that the gantry or corresponding structureis rigid enough to prevent unacceptable vibrations and deflections, so that opti-mum performance can be achieved.

There are two holes in the bot-tom plate which must besealed with plastic plugs, partno. 2522 2101-9. This appliesonly to suspended configura-

tion.

If the robot is converted fromsuspended to floor-mountedconfiguration, remove theplugs. (They are suppliedloose together with the robotfor floor-mounting).




2.5 Stress forces

2.5.1 Stiffness

The stiffness of the foundation must be designed to minimize the influence on thedynamic behaviour of the robot. For optimal performance the frequency of the founda-tion with the robot weight must be higher than 30 Hz.TuneServo can be used for adapting the robot tuning to a non-optimal foundation.

2.5.2 IRB 2400/10, /16

Endurance load Max. load

(In operation) (Emergency stop)

Force xy ± 2000 N ± 2600 N

Force z, standing 4100 ± 1400 N 4100 ± 1900 N

Force z, suspended - 4100 ± 1400 N - 4100 ± 1900 N

Torque xy ± 3400 Nm ± 4000 Nm

Torque z ± 550 Nm ± 900 Nm

Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 5).

2.5.3 IRB 2400L

Endurance load Max. load(In operation) (Emergency stop)

Force xy ± 1700 N ± 2100 N

Force z, standing 4100 ± 1100 N 4100 ± 1400 N

Force z, suspended - 4100 ± 1100 N - 4100 ± 1400 N

Torque xy ± 3000 Nm ± 3400 Nm

Torque z ± 450 Nm ± 900 Nm

Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 5).




Figure 5 The directions of the stress forces.

2.6 Amount of space required

The amount of working space required (same for both floor and inverted mounted) to oper-ate the manipulator is illustrated in Figure 6, Figure 7.The working range for axis 1 is +/- 180°.

NB: There are no software or mechanical limits for the working space under the baselevel of the manipulator.

X

Z




2.6.1 Manipulator

Figure 6 The amount of working space required for IRB 2400L.

560

1810

1189

2885

1702

3421




Figure 7 The amount of working space required for IRB 2400/10, /16.

1550

2458

274

1002

1441

2900

393




2.7 Manually Releasing the brakes

All axes are equipped with holding brakes. If the positions of the manipulator axes are to bechanged without connecting the controller, an external voltage supply (24 V DC) must be con-

nected to enable engagement of the brakes. The voltage supply should be connected to the con-tact at the base of the manipulator or to the Burndy contact in the base under the cover if, option640 is chosen (see Figure 8).

Figure 8 Connection of external voltage to enable engagement of the brakes.

External power must be connected according to Figure 8. Incorrectly connected powercan release all brakes, causing simultaneously movement of all axes.

When the controller or the voltage device is connected as illustrated above, the brakes can beengaged separately using the push-buttons on the connection plate at the rear of the base. Thepush-buttons are marked with the appropriate axis name. The names of the axes and their

motion patterns are shown in Figure 9.

+ 24 V DC

0 V C10

NOTE!Be careful not tointerchange the24 V- and 0 Vpins.

In they are mixedup, damage canbe caused to aresistor and thesystem board.

+24 V B8

12

4 5 6

78 9 1

10 11 12

13 14 15

3

Burndy contact: R1.MP4-6

0 V




WARNING: Be very careful when releasing the brakes. The axes become activatedvery quickly and may cause damage or injury.

Figure 9 The robot axes and motion patterns.

2.8 Restricting the working space

When installing the manipulator, make sure that it can move freely within its entire working

space. If there is a risk that it may collide with other objects, its working space should belimited mechanically for axes 2 and 3 with extra stop lugs and axis 3 with limit switches,and also by using software.

Special kits for limitation of the working space can be ordered. Installation of extra stopsfor the main axes 1 and 2 and installation of switches on axis 3 is described below.

Limiting the working space using software is described in the System Parameters in theUser’s Guide.

Axis 6

Axis 5Axis 4

Axis 3

Axis 2

Axis 1




2.8.1 Axis 1

The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to thebase (Figure 10).

CAUTION! The original stop pin must not be removed under any circumstances.

Figure 10 Location of extra stop lugs.

When drilling holes for extra stop lugs, see Figure 11.

Item Qty Article No. Name Dimension

1 2 3HAB 7310-1 Stop axis 1, removable

2 4 9ADA 312-9 Plain washer 13x24x2.5

3 4 9ADA 183-65 Hex socket head cap screw M12x30 8.8




NOTE 1Only this mounting direction.

NOTE 2

Make a copy and cut out the drilling pattern (Figure 12) and use it to mark out the location ofthe two holes on each stop. Drill the holes through, 10.2, cut threads, M12. Mount the stopswithout thightening the screws. Turn axis 1 manually and check the working range betweenthe stops. If necessary correct the angle of impact.Tighten the screws.

Figure 11 Where to drill the holes for the extra stop lugs.

Min. working range

Max. workingrange

Note 1Note 1

Note 2

Center lines for thehidden stiffening ribs

Drilling not allowedinside this sector




Figure 12 Drilling pattern.

R 264 mm

∅ 10.2 (x2)

1 4 9

5 0

2 0

32

60

Scale 1:1




2.8.2 Axis 2

The range of rotation for axis 2 can be limited mechanically by fitting extra stop lugs

on the lower arm, see Figure 13.

Figure 13 Mechanically limiting axis 2.




Number of parts needed for different angles are shown in the table below:

Item number, see Figure 13

1 2 3

Working range Qty

+110o / -100o - - -

+110o / -70o 1 2 2

+110o / -40o 2 2 4

+80o

/ -100o

1 2 2

+80o / -70o 2 2 4

+80o / -40o 3 2 6

+50o / -100o 2 2 4

+50o / -70o 3 2 6

+50o / -40o 4 2 8

+20o / -100o 3 2 6

+20o / -70o 4 2 8

+20o / -40o 5 2 10




2.8.3 Axis 3

The working range of axis 3 can be limited by fitting an electric switch on the gear box axis

3, which senses the position via a cam, see Figure 14.

Figure 14 Mounting of electrical stop axis 3.




2.9 Unlimited working range axis 4

N.B. Only valid for IRB 2400/10, /16.

The function “Resetting the work area for an axis”, included in Advanced motions 3.0, canalso be used for axis 4. To enable useage of this function, the mechanical stop on axis 4should be removed. Follow the procedure below to dismantle the mechanical stop. See alsoFoldout 7 in Spare Parts List.

1 Loosen the four screws <32> and dismantle the cover.

2 Slowly rotate axis 4 until the damper <30> is visible through the hole.

3 Remove the damper.

4 Remount the cover and tighten the screws with 15 Nm.

Note that when the damper is removed, axis 4 does not have a mechanical stop. If the robotis provided with cabling on the upper arm, e.g. option 04y, the cabling can be damagedwhen the function “Resetting the work area for an axis” is used, or if the robot is joggeduncalibrated.




2.10 Mounting holes for equipment on the manipulator

NB: Never drill a hole in the manipulator without first consulting ABB Flexible

Automation.

Figure 15 Holes for extra equipment, IRB 2400 (Dimensions in mm).

IRB 2400/10 and IRB 2400/16

11085 463 65

7 0

177

M8 (3x)Depth of tread 14

1 3 5

2 5

37

70

M5 (2x)Depth 6

M8 (2x)Depth 14

150135

IRB 2400L

M6 (2x) 3 5

65




Figure 16 Holes for extra equipment, IRB 2400 (Dimensions in mm)

If the option 623 is mounted, this option occupies the holes on the gearbox axis 3 side.

M5 (2x)

22

43

78 90

38o

M8 (3x) depth 16

IRB 2400/10 and IRB 2400/16

IRB 2400L

82

120o

120o 120o

120o

38o

R = 77

M8 (3x) depth 16R = 92




.

Figure 17 The mechanical interface of IRB 2400L (mounting flange).

Figure 18 The mechanical interface of IRB 2400/10 and IRB 2400/16 (mounting flange).

2.11 Loads

Regarding load diagram, permitted extra loads (equipment) and location of extra loads(equipment), see chapter 3.4 in Product Specification IRB 2400 (Technical specifica-tion). The loads must also be defined in the soft ware, see User´s Guide.

4 5 o

D=6 H7

M6 (4x)

R=20

A

A

∅ 0.05 B

(4x)90o

6

D = 2 5

9

A - A

D = 5 0

h 8

B

H 8

+ 0 . 0

2 7

- 0

+ 0 - 0

. 0 3 9

+0.012-0

7

D = 3 1 , 5

8

D=6+0.012-0

M6 (6x)

6 0 o

3 0 o

A - A

A

A

R=25

0.05 B

D = 6 3

h 8

B

5 x

H7

H 8

The hole can go through

+ 0 . 0

3 9

- 0

+ 0 - 0 . 0

4 6



Installation and CommissioningCustomer connections on manipulator

3 Customer connections on manipulator

For connection of extra equipment on the manipulator, there are cables and air hoseintegrated into the manipulator’s cabling, one Burndy 23-pin UTG 018-23S and oneburndy 12-pin UTG 014-12S connector on the rear part of the upper arm.

Connections: R1/4” in the rear part of the upper arm and at the base. Max. 8 bar.Inner hose diameter: 8 mm.

N.B The air hose is sensitive to wear because it is part of the moving cable harness.The risk of failure is greater in this case compared with a hose that is stationaryand clamped.

When option 04y is chosen, the customer connections are available at the front of the

upper arm.

Number of signals:

Figure 19 Location of customer connections, IRB 2400/10, /16.

Figure 20 Location of customer connections, IRB 2400L.

IRB 2400/10 and /16 23 (50 V, 250 mA), 10 (250 V, 2 A), one protective earth.

IRB 2400L 12 (60 V, 500 mA)

R3.CP

R3.CS

R2.CP

R2.CS

R1.CP/CS

Air R1/4”

Air R1/4”

Air R1/4”

R1.CSAir R 1/4”

R2.CSAir R 1/4”



Customer connections on manipulator Installation and Commissioning

To connect to power and signal conductors from the connection unit to the manipulatorbase and on the upper arm, the following parts are recommended:

IRB 2400

Figure 21 Customer connector.

Connector R1.CP/CS Power and Signals on the manipulator base.

(Regarding Item No see Figure 21)

Item

No

Name ABB art. no Type Comments

1 Female insert 40p 3HAB 7284-1 DIN 43 652

2 Hood 3HAB 7285-1 DIN 43 652

3 Compression gland 3HAB 7283-1 DS/55 ZU, DN

155D, E155

PFLITSCH

4 Socket 5217 1021-4 DIN 43 652 0.14-0.5 mm

2

5 Sockets 5217 1021-5 DIN 43 652 0.5-1.5 mm2

6 Key pin 5217 687-9 DIN 43 652

14 5

2

3

6




Figure 22 Customer connector (Foundry).

Connector R1.CP/CS Power and Signals on the manipulator base.


ItemNo


1 Female insert 40p 3HAB 7284-1 DIN 43 652

2 Hood 3HAB 8272-1 IP 68

3 Compression gland 3HAB 3407-1 IP 68

4 Socket 5217 1021-4 DIN 43 652 0.14-0.5 mm2

5 Socket 5217 1021-5 DIN 43 652 0.5-1.5 mm2

6 Key pin 5217 687-9 DIN 43 652




IRB 2400

Connector R2.CS/R3.CS Signals on the upper arm.


ItemNo


1 Socket con. 23p 3HAC 7446-4 UTO718 23SH44N FCI

2 Socket See table below

3 Pin connector 23p 3HAC 7907-4

4 Pin connector 23p 3HAC 7455-4 UTO 618 23 P45N FCI

5 Pin See table below

6 Adaptor 3HAC 7434-2 UTG 18 AD Burndy

7 Shrinking hose 3HAA 2614-3 Bottled shaped

8 Shrinking hose 5217 1032-5 Angled




IRB 2400

Connector R2.CP./R3.CP. Power on the upper arm.


Item

NoName ABB art. no Type Comments

1 Socket connector 3HAC 7446-3 UT 07 14 12 SH 44N Burndy

2 Socket See table below

3 Pin connector 12p 3HAC 7907-1 UTO 61412 P45N

4 Pin connector 12p 3HAC 7455-3 UTO 61412 P45N

5 Pin See table below

6 Adaptor 3HAC 7434-1 UTG 14 ADN Burndy

7 Shrinking hose 3HAA 2614-2 Bottled shaped

8 Shrinking hose 5217 1032-4 Angled


Pin 5217 649-72

5217 649-25

5217 649-70

5217 649-35217 649-68

5217 649-10

5217 649-31

24/26

24/26

20/22

20/2216/20

24/26

16/20

Burndy Machine tooling

Burndy Hand tooling


Burndy Hand toolingBurndy Machine tooling

Burndy Ground

Burndy Ground

Socket 5217 649-73

5217 649-26

5217 649-71

5217 649-69

5217 1021-4

5217 1021-5

24/26

24/26

20/22

16/18

DIN 43 652

DIN 43 652


Burndy Hand tooling



Tin bronze (CuSu)

0.14 - 0.5mm2 AWG 20-26

Tin bronze (CuSu)

0.5 - 1.5mm2 AWG 16-20




Figure 23 Burndy connector.

7, 86

4, 5

3, 5

1, 2




3.1 Connection of extra equipment to the manipulator

Technical data for customer connections

Cutsomer Power CP

Conductor resistance <0,5 ohm, 0,241 mm2

Max. voltage 250 V ACMax. current 2 A

Customer Signals CS

Conductor resistance <3 ohm, 0.154 mm2

Max. voltage 50 V AC / DCMax. current 250 mA

3.1.1 Connections on upper arm, IRB 2400/10, /16

Figure 24 Customer connections on upper arm.

Signal name Customer terminalcontroller,

see Prod. Manual for

S4Cplus (optional)

Customer contacton upper arm, R2

Customer contact on

manipulator base

(cable not supplied)

Power supply

CPA XT6.1 R2.CP.A RI.CP/CS.A1

CPB XT6.2 R2.CP.B RI.CP/CS.B1

CPC XT6.3 R2.CP.C RI.CP/CS.C1

CPD XT6.4 R2.CP.D RI.CP/CS.D1CPE XT6.5 R2.CP.E RI.CP/CS.A2

CPF XT6.6 R2.CP.F RI.CP/CS.B2

R2.CP.GGround RI.CP/CSP Ground

XT6.H R2.CP.HKey pin

CPJ XT6.7 R2.CP.J RI.CP/CS.C2

CPK XT6.8 R2.CP.K RI.CP/CS.D2

CPL XT6.9 R2.CP.L RI.CP/CS.A3

CPM XT6.10 R2.CP.M RI.CP/CS.B3

Signals

CSA XT5.1 R2.CS.A R1.CS/CP.B5

CSB XT5.2 R2.CS.B R1.CS/CP.C5

CSC XT5.3 R2.CS.C R1.CS/CP.D5

CSD XT5 4 R2 CS D R1 CS/CP A6

Air R1/4”R2.CSR2.CP




3.1.2 Connections on upper arm, IRB 2400L

Figure 25 Customer connections on upper arm.

CSE XT5.5 R2.CS.E R1.CS/CP.B6

CSF XT5.6 R2.CS.F R1.CS/CP.C6

CSG XT5.7 R2.CS.G R1.CS/CP.D6

CSH XT5.8 R2.CS.H R1.CS/CP.A7

CSJ XT5.9 R2.CS.J R1.CS/CP.B7CSK XT5.10 R2.CS.K R1.CS/CP.C7

CSL XT5.11 R2.CS.L R1.CS/CP.D7

CSM XT5.12 R2.CS.M R1.CS/CP.A8

CSN XT5.13 R2.CS.N R1.CS/CP.B8

CSP XT5.14 R2.CS.P R1.CS/CP.C8

CSR XT5.15 R2.CS.R R1.CS/CP.D8

CSS XT5.16 R2.CS.S R1.CS/CP.A9

CST XT5.17 R2.CS.T R1.CS/CP.B9

CSU XT5.18 R2.CS.U R1.CS/CP.C9

CSV XT5.19 R2.CS.V R1.CS/CP.D9

CSW XT5.20 R2.CS.W R1.CS/CP.A10

CSX XT5.21 R2.CS.X R1.CS/CP.B10

CSY XT5.221 R2.CS.Y R1.CS/CP.C10

CSZ XT5.23 R2.CS.Z R1.CS/CP.D10

R2.CS



Maintenance

CONTENTSPage

1 Maintenance intervals ............................................................................................. 3

2 Instructions for Maintenance ................................................................................. 4

2.1 Oil in gears ...................................................................................................... 4

2.2 Signal cabling upper arm ................................................................................ 4

2.3 Changing the battery in the measuring system ............................................... 4

2.4 Checking the mechanical stop, axis 1 ............................................................. 6

2.5 RAM Battery lifetime ..................................................................................... 6



Maintenance

CONTENTSPage



Maintenance

Maintenance

The robot is designed to be able to work under very demanding circumstances with aminimum of maintenance. Nevertheless, certain routine checks and preventative main-tenance 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 wipeit with a cloth. Compressed air and harsh solvents that can damage thesealing joints, bearings, lacquer or cabling must not be used.

1 Maintenance intervals

MANIPULATOR

Prescribed maintenance

Maintenance intervals,

time in operation

Check twice a

year4000 hrs

(1 year with

two shift)

12 000 hrs

(3 years with

two shift)

Others

Measuring system

Change battery3 years1

1. See section 2.3.

Change the signal cabling

upper arm, if option 04y

X

Mechanical stop axis 1

Have to be

changed if

bent.

Wrist unit

Change oil

X2

2. Change for the first time after 1 year or 4000 hours, after that every five years.

X3

3. Is only needed if the robot is working in an enviroment temperature over 40o C.

5 years



Maintenance

2 Instructions for Maintenance

2.1 Oil in gears

The gearboxes for axes 1, 2, 3 and 4 are lubricated for life with oil, which correspondsto 40 000 hours in operation.

Oil in gearboxes 5 and 6 must be changed at the intervals specified in the maintenancetable. The oil is checked and changed as described in the chapter Repairs, section Oilchange in gearboxes.

2.2 Signal cabling upper arm

The cabling must be changed at intervals specified in the maintenance table. The

cabling is changed as described in the chapter Repairs, section Cabling and Measuringboard.

2.3 Changing the battery in the measuring system

The battery to be replaced is located in the base (see Figure 1).

The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with arti-cle number 4944 026-4.

The battery must never be just thrown away; it must always be handled as hazardouswaste.

• Set the robot to the MOTORS OFF operating mode. (This means that it will not haveto be coarse-calibrated after the battery change.)

• Loosen the battery terminals from the serial measuring board and cut the clasp thatkeep the battery unit in place.

• Install a new battery with a clasp and connect the terminals to the serial measuringboard.



Maintenance

• The battery takes 36 hours to recharge; the mains supply must be switched on duringthis time and there must not be any power interrupts.

Figure 1 The battery is located in the base.

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 has for that reason a blocking diode whichprevents charging from the serial measurement board.

The benefit with a lithium battery is the lifetime, which can be up to 5 years in service,compare with the Ni-Cd battery’s max life time of 3 years in service.

Two lithium batteries exists:

- a 3-cell battery, art.no. 3HAB 9999-1

- a 6-cell battery, art.no. 3HAB 9999-2

The life time of the lithium battery depends on how frequently the user switches off thepower. The estimated max life time in years for the different lithium batteries and therecommended exchange interval is shown below:

* Because of material ageing the maximum life time in service is 5 years.

Voltage of batteries, measured at power off:

Exchange of the battery is done according to the first section of this chapter.

User type: Exchange 3-cell: Exchange 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

Min Max.

Ni-Cd 7.0 V 8.7 V

Lithium 7.0 V -

Remove the cover to get access tothe battery.



Maintenance

2.4 Checking the mechanical stop, axis 1

Check regularly, as follows:

Stop pin:

- that the pin is not bent.If the stop pin is bent, it must be replaced by a new one.The article number of the pin is 3HAB 6687-1

2.5 RAM Battery lifetime

The maximum service lifetime of the battery is five years. The lifetime is influenced bythe installed memory board type and by the length of time the system is without power.

The following table indicates the minimum time, in months, that memory will be held

if the system is without power:

A battery test is performed during the following occasions:

1. System diagnostics (before software installation). Failing test results in one of thefollowing messages on the display:

- “Warning: Battery 1 or 2 < 3.3V” i.e. one of the batteries is empty.

- “Error: Battery 1 and 2 < 3.3V” i.e. both batteries are empty.

2. Warm start. Failing test results in one of the following messages on the display:

- 31501 Battery voltage too low on battery 1.

- 31502 Battery voltage too low on battery 2.

- 31503 Battery voltage too low on both batteries.

Memory board size First battery Both batteries

4 MB 6 12

6 MB 5 10

8 MB 6.5 13

16 MB 5 10



Repairs

CONTENTSPage

1 General Description ........................................................................................................ 3

1.1 Instructions for reading the following chapters...................................................... 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 .................................................................. 8

1.5 Tightening torques .................................................................................................. 9

1.5.1 Screws with slotted or cross recessed head.................................................. 9

1.5.2 Screws with hexagon socket head................................................................ 9

2 Axis 1 ................................................................................................................................ 11

2.1 Replacing the motor for axis 1 ............................................................................... 11

2.2 Changing the gearbox............................................................................................. 12

2.3 Replacing the mechanical stop ............................................................................... 13

3 Axis 2 ................................................................................................................................ 15

3.1 Changing the motor for axis 2 ................................................................................ 15


3.3 Dismantling the lower arm ..................................................................................... 16

3.4 Changing the bearing in the lower arm .................................................................. 184 Axis 3 ................................................................................................................................ 19

4.1 Changing the motor for axis 3 ................................................................................ 19


4.3 Dismantling the parallel arm .................................................................................. 20

4.4 Changing the tie rod ............................................................................................... 21

4.5 Dismantling the complete upper arm...................................................................... 22

5 Axes 4-6 (IRB 2400/10/16) .............................................................................................. 25

5.1 Replacing the motor................................................................................................ 255.2 Dismounting the wrist ............................................................................................ 27

5.3 Dismounting the mechanical stop for axis 4 .......................................................... 28

6 Axes 4-6 (IRB 2400L)...................................................................................................... 29

6.1 Axis 4...................................................................................................................... 29

6.1.1 Changing the motor...................................................................................... 29

6.1.2 Changing the intermediate gear including sealing....................................... 30

6.1.3 Changing the drive gear on the tubular shaft ............................................... 31

6.1.4 Changing bearings of the tubular shaft ........................................................ 33

6.2 The Wrist and Axes 5 and 6 ................................................................................... 33



Repairs

CONTENTSPage

6.2.1 Dismantling the wrist................................................................................... 34

6.2.2 Changing the drive shaft unit, gear belts or motors..................................... 34

6.2.3 Changing the motor or driving belt of axes 5 and 6 .................................... 367 Push-button unit for brake release................................................................................ 37

7.1 General description................................................................................................. 37

8 Cabling and Measuring board....................................................................................... 39

8.1 Changing serial measuring board ........................................................................... 39

8.2 Changing the cabling in axes 1,2 and 3.................................................................. 39

8.3 Changing the cabling in axes 4, 5 and 6................................................................. 40

8.4 Changing the signal cabling axis 4, option 04y...................................................... 40

9 Motor units ...................................................................................................................... 43

9.1 General ................................................................................................................... 43

10 Oil change in gearboxes ................................................................................................ 45

10.1 Oil in gearboxes 1-3 (IRB 2400L/10/16) ............................................................. 45

10.2 Oil in gearboxes 4-6 (IRB 2400/10/16)................................................................ 45

10.3 Oil in gearboxes 4-6 (IRB 2400L) ....................................................................... 45

10.4 Oil plugs, axes 4-6 (IRB 2400/10/16) .................................................................. 46

10.5 Oil plugs, axes 5-6 (IRB 2400L) .......................................................................... 46

10.6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16)........................... 46

10.7 Changing and checking the oil in gearbox 4 (IRB 2400L) .................................. 47

10.8 Changing and checking the oil in gearboxes 5 and 6 .......................................... (IRB2400/10/16)............................................................................................................ 47

10.9 Changing and checking the oil in gearboxes 5 and 6 .......................................... (IRB2400L).................................................................................................................... 48

11 Calibration ..................................................................................................................... 49

11.1 General.................................................................................................................. 49

11.2 Adjustment procedure using calibration equipment (fine calibration)................. 49

11.3 Setting the calibration marks on the manipulator................................................. 55

11.4 Checking the calibration position......................................................................... 59

11.5 Alternative calibration positions........................................................................... 59

11.6 Calibration equipment .......................................................................................... 61

11.7 Operating the robot............................................................................................... 61



Repairs General Description

1 General Description

The IRB 2400 industrial robot system comprises two separate units: the control cabinetand the manipulator. Servicing the mechanical unit is described in the subsequent chap-ters.

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 feedsthe motor units of the manipulator axes. The signal cabling feeds the various controlparameters, such as axis positions, motor revs, etc.

The AC Motor Units provide the motive power for the various manipulator axes, driv-ing them through gearboxes. Mechanical brakes, electrically released, lock the motorunits when the robot is inoperative for more than 3 minutes during both automatic oper-ation and manual operation.

The Mechanical System has 6 axes which make its movements very flexible.

Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion.The lower arm, together with the radius rod and the parallel bracket, form a parallelo-gram relative to the upper arm. The parallel bracket is mounted on bearings in theradius rod and in the upper arm.

Axis 3 raises the upper arm of the manipulator. Axis 4, located on the upper arm,rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes5 and 6. These axes form a cross.

Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customertools on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumat-ically controlled by means of an external air supply (optional extra). The signals to/

from the tool can be supplied via internal customer connections (optional extras).

Note that the control cabinet must be switched off during all maintenance workon the manipulator. The accumulator power supply must always be disconnectedbefore performing any work on the manipulator measurement system (measure-ment boards, cabling, resolver unit).

When any type of maintenance work is carried out, the calibration position of themanipulator must be checked before the robot is returned to the operational mode.

A brake release unit can be connected as described in chapter 7, Push-button unit forbrake release, to enable movement of the axes.

Take special care when manually operating the brakes. Make sure also that thesafety instructions in this manual are followed when starting to operate the robot






1.2 Caution

The mechanical unit contains several parts which are too heavy to lift manually.As these parts must be moved with precision during any maintenance and repairwork, it is important that suitable lifting equipment is available.

The robot should always be switched to MOTORS OFF before anybody is allowedto enter its working space.

1.3 Fitting new bearings and seals

1.3.1 Bearings

1. Do not unwrap new bearings until just before assembly, in order to prevent dustand grit getting into the bearing.

2. Make sure that all parts of the bearing are free from burr dust, grinding dustand any other contamination. Cast parts must be free from foundry sand.

3. Bearing rings, races and roller parts must not under any circumstances besubjected to direct impact. The roller parts must not be subjected to any pressurethat is created during the assembly.

Tapered bearings

4. The bearing should be tightened gradually until the recommended pre-tensioningis attained.

5. The roller parts must be rotated a specified number of turns both before pre-tensioning and during pre-tensioning.

6. The above procedure must be carried out to enable the roller parts to slot intothe correct position with respect to the racer flange.

7. It is important to position the bearings correctly, because this directly affects theservice life of the bearing.

Greasing bearings

8. Bearings must be greased after they are fitted. Extreme cleanliness is necessarythroughout. A high quality lubricating grease, such as 3HAB 3537-1, should beused.

9. Grooved ball bearings should be greased on both sides.



General Description Repairs

10. Tapered roller bearings and axial needle bearings should be greased when theyare split.

11. Normally the bearings should not be completely filled with grease. However, ifthere is space on both sides of the bearing, it can be filled completely with greasewhen it is fitted, as surplus grease will be released from the bearing on start up.

12. 70-80% of the available volume of the bearing must be filled with grease duringoperation.

13. Make sure that the grease is handled and stored correctly, to avoid contamination.

1.3.2 Seals

1. The most common cause of leakage is incorrect installation.

Rotating seals

2. The seal surfaces must be protected during transportation and assembly.

3. The seals must either be kept in their original packages or be protected well.

4. The seal surfaces must be inspected before installation. If the seal is scratched ordamaged in such a way that it may cause leakage in the future, it must be replaced.

5. 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.

6. Grease the seal just before it is fitted – not too early as otherwise dirt and foreignparticles may stick to the seal. The space between the dust tongue and sealing lipshould be 2/3 filled with grease of the type 3HAB 3537-1. The rubber coatedexternal diameter must also be greased.

7. Seals and gears must be fitted on clean workbenches.

8. Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumpingstarts.

9. Always use an assembling tool to fit the seal. Never hammer directly on theseal because this will cause it to leak.

10. Use a protective sleeve on the sealing edge during assembly, when sliding overthreads, key-ways, etc.




Flange seals and static seals

11. 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).

12. The surfaces must be even and free from burr dust (caused by incorrect machin-ing). If the flange surfaces are defective, they must not be used as they will causeleakage.

13. The surfaces must be cleaned properly in the manner recommended by ABBROBOTICS.

14. Distribute the sealing compound evenly over the surface, preferably using a brush.

15. Tighten the screws evenly around the flange joint.

16. Make sure that the joint is not subjected to loading until the sealing compound hasattained the hardness specified in the materials specification.

O-rings

17. Check the O-ring grooves. The grooves must be geometrically correct, withoutpores and free of dust and grime.

18. Check the O-ring for surface defects and burrs, and check that it has the correctshape, etc.

19. Make sure the correct O-ring size is used.

20. Tighten the screws evenly.

21. Defective O-rings and O-ring grooves must not be used.

22. 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

The following tightening torques must be used for all screw joints made of metallicmaterials – unless otherwise specified in the text.

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 withGleitmo.

When handling screws treated with Gleitmo, protective gloves of nitrile rubbertype should be used.

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times beforethe slip coating disappears. Screws can also be treated with Molycote 1000.

When screwing in new screws without Gleitmo, these should first be lubricated withMolycote 1000 and then tightened to the specified torque.

Assembly

Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote1000 should only be used when specified in the text.

Screws sized M8 or larger should be tightened with a torque wrench, if possible.

Screws sized M6 or smaller may be tightened to the correct torque by personnel withsufficient mechanical training, without using torque measurement tools.




1.5 Tightening torques

1.5.1 Screws with slotted or cross recessed head

1.5.2 Screws with hexagon socket head

Tightening torque - Nm

Dimension Class 4.8“Dry”

M 2.5 0.25

M 3 0.5

M 4 1.2

M 5 2.5

M 6 5.0

Tightening torque - Nm

Dimension Class 8.8

“Dry”

Class 10.9

Molycote 1000Gleitmo 610

Class 12.9

Molycote 1000Gleitmo 610

M 5 6

M 6 10 15

M 8 24 28 35

M 10 47 55 70

M 12 82 95 120

M 16 200 235 300






Repairs Axis 1

2 Axis 1

2.1 Replacing the motor for axis 1

See foldouts 1 and 5 in the list of spare parts.

The motor and the drive gear constitute one unit.

To dismantle:

1. Remove the cover of the connection box.

2. Loosen connectors R3.MP1 and R3.FB1.

3. Remove the connection box by unscrewing <5/137>.

4. Note the position of the motor before removing it.

5. Loosen the motor by unscrewing <1/9>.

To assemble:

6. Check that the assembly surfaces are clean and the motor unscratched.

7. Mount the O-ring <1/6>.

8. Install the motor, tighten screws <1/9> using a torque of 2 Nm.

Note the position of the motor

9. Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3.MP1 con-nector.

10. Mount tool no. 3HAB 7887-1 at the rear of the motor.

11. Turn the motor shaft a couple of turns, with help of the tool.

12. Place the tip of a dial indicator against the scribed mark on the measuring tool.

The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft.

13. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicatorof 0.13 mm.

14. Pull gently in one direction. Note the reading. (The gear must not turn.)



Axis 1 Repairs

15. Then gently knock on the tool in the other direction and note the reading. The dif-ference in reading = gear play. The gear play should be 0.02 mm which corre-sponds to a reading on the dial indicator of 0.13 mm.

16. Tighten screw <1/9> with a torque of 15 Nm.

17. Fill with oil. See chapter 10, Oil change in gearboxes.

18. Connect the cabling.

19. Calibrate the robot as specified in chapter 11, Calibration.

Tightening torque:

Motor attaching screws, item 9: 15 Nm

2.2 Changing the gearbox

Axis 1 gearbox is of the conventional type, manufactured with high precision, andtogether with the gearboxes for axes 2 and 3, forms a complete unit.

The gearbox is not normally serviced or adjusted.

Note: If there is reason to change a gearbox on any of the axes 1, 2 or 3, then the wholeunit must be changed.

See foldouts 1, 2 and 3 in the list of spare parts.

To dismantle:

1. Remove the cabling and serial measuring boards as described inchapter 8, Cablingand Measuring board.

2. Remove the tie rod as described in chapter 4.4, Changing the tie rod.

3. Dismantle the upper arm as described in chapter 4.5, Dismantling the complete

upper arm.

4. Remove the parallel arm as described in chapter 4.3, Dismantling the parallel arm.

5. Dismantle the lower arm as described in chapter 3.3, Dismantling the lower arm.

6. Remove the motors on axes 1, 2 and 3 as described in sections chapter 2.1, Replac-ing the motor for axis 1, chapter 3.1, Changing the motor for axis 2 and chapter 4.1,Changing the motor for axis 3.

7. Place the remaining parts of the manipulator upside-down on a table or similar sur-face and remove the bottom plate <3/102>.

Make sure that the foot is stable.



Repairs Axis 1

8. Undo screws <1/3>.

9. Separate the base from the gearbox unit.

To assemble:

10. Place a new gearbox unit on the table.

11. Raise the base.

12. Screw in the screws <1/3> together with their washers <1/4>. Tighten using atorque of 54 Nm.

13. Replace the bottom plate <3/102> using screws <3/120>.

14. Turn the base.

15. Replace the lower arm as described in chapter 3.3, Dismantling the lower arm

16. Replace the parallel arm as described in chapter 4.3, Dismantling the parallel arm.

17. Replace the upper arm as described in chapter 4.5, Dismantling the completeupper arm.

18. Replace the cabling as described in chapter 8, Cabling and Measuring board.

19. Replace the tie rod as described in chapter 4.4, Changing the tie rod.

20. Calibrate the robot as described in chapter 11, Calibration.

Tightening torque:

Screwed joint of base/gearbox unit, item <1/3>: 54 Nm

2.3 Replacing the mechanical stop

See foldout 1 in the list of spare parts.

If the stop pin is bent, it must be replaced.

1. Remove screw <134>.

2. Lift the stop away.

To assemble:

3. Place a new stop in position.

4. Tighten screw <134>.



Axis 1 Repairs



Repairs Axis 2

3 Axis 2

3.1 Changing the motor for axis 2



To dismantle:

Lock the arm system before dismantling the motor; the brake is located in themotor.





5. Loosen the motor by unscrewing <1/8, 1/9>. N.B. The oil will start to run out.

To assemble:



8. Install the motor, tighten screws <1/8>, 1/9> using a torque of 2 Nm.

Note the position of the motor and the location of the two screws <1/8>.










Axis 2 Repairs

15. Then gently knock on the tool in the other direction and note the reading. The dif-ference in reading = gear play. The gear play should be 0.02 mm which corre-sponds to a reading on the dial indicator of 0.13 mm.

16. Tighten screw <1/8, 1/9> with a torque of 15 Nm.




Tightening torque:

The motor’s fixing screws, item 8, 9: 15 Nm


Axis 2 gearbox is of a conventional type, manufactured with high precision, andtogether with the gearbox for axes 1 and 3, forms a complete unit.


Note: If there is reason to change a gearbox on any of the axes 1, 2 or 3, the whole unitmust be changed.

To dismantle:

See chapter 2.2, Changing the gearbox.

3.3 Dismantling the lower arm


To dismantle:

1. Remove the cabling down to axis 1 as in chapter 8, Cabling and Measuring board.

2. Dismantle the upper arm as in chapter 4.5, Dismantling the complete upper arm.

3. Attach the crane to the lower arm.

4. Remove the parallel arm as in chapter 4.3, Dismantling the parallel arm.

5. Loosen screws <12>.

6. Take off the lower arm.



Repairs Axis 2

To assemble:

7. Transfer the damping element and calibration marking to the new lower arm.

8. Lift the lower arm into position.

9. Fix the lower arm to gearbox 2 using screws <12> and tighten to a torque of68 Nm.

To prevent clicking during operation of the robot, grease the bearing seat of theparallel arm in the lower arm.

10. Mount the parallel arm as in chapter 4.3, Dismantling the parallel arm.

11. Replace the upper arm as in chapter 4.5, Dismantling the complete upper arm.

12. Replace the cabling as in chapter 8, Cabling and Measuring board.

13. Calibrate the robot as in chapter 11, Calibration.

Tightening torque:

Screwed joint of lower arm/gearbox 2, item <12>: 68 Nm



Axis 2 Repairs

3.4 Changing the bearing in the lower arm


To dismantle:

1. Dismount the tie rod as in chapter 4.4, Changing the tie rod.

Loosen the screws <3/135> so that the cables can moved a bit.

2. Attach a hoist to the parallel arm.

3. Unscrew screws <2/17> which hold the parallel arm to gearbox 3 and remove it.

4. Remove the bearing from the parallel arm.

To assemble:

5. Mount V-ring <2/19>.

6. Mount seal ring <2/21> on the parallel arm.

Heat up the bearing <2/20> to 170 o C before mounting it on the parallel arm.

7. Fit a new bearing <2/20> on the parallel arm.

8. Mount the other seal ring <2/21> on the parallel arm.

9. Replace the screws <2/17> and tighten to a torque of 68 Nm.

10. Mount the tie rod as in chapter 4.4, Changing the tie rod.

11. Mount screws <3/135> and tighten.


Tightening torque:

Screwed joint of parallel arm/gearbox 3, item <2/17>: 68 Nm



Repairs Axis 3

4 Axis 3

4.1 Changing the motor for axis 3



To dismantle:

Lock the arm system before dismantling the motor; the brake is located in themotor.





5. Loosen the motor by unscrewing <1/8, 1/9>. N.B. The oil will start to run out.

To assemble:



8. Install the motor, tighten screws <1/8, 1/9> using a torque of 2 Nm.

Note the position of the motor and the location of the two screws <1/8>.










Axis 3 Repairs

15. Then gently knock in the other direction and note the reading. The difference inreadings = gear play. The gear play should be 0.02 mm which corresponds to areading on the dial indicator of 0.13 mm.

16. Tighten screw <1/8, 1/9> with a torque of 15 Nm.




Tightening torque:

The motor fixing screws, item 8, 9: 15 Nm


Axis 3 gearbox is of a conventional type, manufactured with high precision, andtogether with the gearboxes for axes 1 and 3, forms a complete unit.


Note: If there is reason to change a gearbox on any of the axes 1, 2 or 3, then the wholeunit must be changed.

To dismantle:

See chapter 2.2, Changing the gearbox.

4.3 Dismantling the parallel arm


To dismantle:


Loosen the screws <3/135> so that the cables can moved a bit.

2. Unscrew screws <2/17> which fix the parallel arm to gearbox 3.

3. Remove the bearing and sealings from the parallel arm.

To assemble:

4. Mount V-ring <2/19>.



Repairs Axis 3

5. Mount seal ring <2/21> on the parallel arm.

Heat up the bearing <2/20> to 170 o C before mounting it on the parallel arm.

6. Fit a new bearing <2/20> to the parallel arm.

7. Mount the other seal ring <2/21> on the parallel arm.

8. Replace the screws <2/17> and tighten to a torque of 68 Nm.


10. Mount screws <3/135> and tighten.


Tightening torque:

Screwed joint of parallel arm/gearbox 3, item <2/17>: 68 Nm

4.4 Changing the tie rod


To dismantle:

Lock the upper arm in a horizontal position with the help of a crane or similar.

1. Unscrew screws <34> and <8/49>.

2. Remove washers <33, 8/50> and seals <35, 8/48>.

3. Insert a screw in the centre, to be used as a support.

4. Use a puller to pull out the tie rod <8/43>.

5. Change the bearings <8/44> and seals <8/45>.

6. Move the mechanical stop.

To assemble:

7. Make sure you replace the rod the correct way up. See foldout 1.

8. Mount new bearings <8/44> and seals <8/48, 8/45>. Use tool 3HAB 6324-1.

9. Mount the tie rod on the manipulator using tool 3HAB 6331-1.

10. Mount washers <33, 8/49> and lock screws <34, 8/49> with Loctite 242.



Axis 3 Repairs

4.5 Dismantling the complete upper arm


To dismantle:

Attach a crane to the upper arm.


2. Loosen the connectors of the motors of axes 4, 5 and 6.

3. Disconnect the connection box from the motors.

4. Remove the covers <1/57>.

5. Undo the KM nuts <1/54>.

6. Remove screws <1/56>.

7. Pull out the shaft. Use tool 3HAB 9009-1. Mark the shafts (left, right).

To assemble:

8. Mount sealings <8/41> in the upper arm.

9. Mount the inner ring of the bearings <8/42> on shafts <1/55>.Use tool no. 3HAB 6464-1.

10. Raise the upper arm into the assembly position.

11. Install shaft spindles <1/55> (both sides).

12. Insert screws <1/56> and tighten with torque 90 Nm.

The following procedure must be performed within 10 minutes, before the Loctite starts to harden.

13. Apply Loctite 242 on the KM-nuts.

14. Tighten the KM-nut on the left side first (robot seen from behind) so that the bearingcomes against the collar.

15. Unscrew the KM-nut and then tighten with a torque of 35 Nm.

16. Tighten the KM-nut on the right side, move the upper arm up and down at the sametime, until there is no play.

17. Unscrew the nut again.

18. Tighten the KM-nut with a torque of 35 Nm.



Repairs Axis 3

19. Mount the covers <1/57>.

Push in a strap from the other under the sealing, so that the air can go out.


21. Mount the sync. plate for axis 3.

22. Reconnect the connection boxes and the cabling.


Tightening torque:

KM nut, item <1/54>: 35 Nm



Axis 3 Repairs



Repairs Axes 4-6 (IRB 2400/10/16)

5 Axes 4-6 (IRB 2400/10/16)

5.1 Replacing the motor



To dismantle:

Valid for axes 4-6.

Lock the arm system before dismantling the motor; the brake is located in the

motor.


2. Drain the oil in the gearbox. Open plug <33> or position the upper arm vertical.

3. Loosen connectors R3.MP(4,5,6) and R3.FB(4,5,6).




To assemble:

Valid for axis 4


8. Mount O-ring <7/27>.


10. Release the brake in motor for axis 4 by applying 24 VDC to terminals 7(+) and 8on the R3.MP4 connector.

11. Seek up the smallest play by turning the motor shaft 6 turns and thereby find thearea with the smallest play within this range.

12. Push the motor radially so that the play becomes minimal within one motor turn,without the gear “chewing”.

13. Fill with oil if drained. See chapter 10, Oil change in gearboxes.




Axes 4-6 (IRB 2400/10/16) Repairs


Valid for axis 5




10. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of90°, totally one whole turn, and thereby find the area where the play for motor 5becomes smallest.

11. Turn the motor for axis 5 one full turn at a time, totally 5 turns. Find where thesmallest play is within this area.





Valid for axis 6




10. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of90°, totally one whole turn, and thereby find the area where the play for motor 6becomes smallest.

11. Turn the motor for axis 5 one full turn at the time, totally 5 turns. Find the smallestplay for axis 6 within this area.

12. Turn the motor for axis 6 one full turn at a time, totally 3 turns. Find the smallestplay for axis 6 within this area.







Repairs Axes 4-6 (IRB 2400/10/16)

Tightening torque:

The motor’s fixing screws, item 28: 11 Nm

5.2 Dismounting the wrist

The wrist, which includes axes 5 and 6, is a complete unit comprising drive units andgearboxes. It is a replacement unit of complex design and should not normally be serv-iced on-site. Instead it should be sent to ABB Flexible Automation for service etc.

ABB Robotics recommends its customers to carry out only the following servicing andrepair work on the wrist.

• Change the oil as shown in the table in chapter 10, Oil change in gearboxes.


To dismantle:

1. Remove the oil plugs on the wrist and drain it as described in chapter 10, Oil changein gearboxes.

2. Undo screws <20> and remove the wrist.

To assemble:

3. Mount O-ring <19> with grease on the wrist.

4. Run the upper arm to a vertical position, wrist side pointing upwards.

5. Mount the wrist. Do not tighten the screws.

6. Release the brakes on axes 5 and 6 (one at the time) and mount tool 3HAB 7887-1at the rear of the motor.

7. Push the wrist, as shown in Figure 1, to locate the smallest play in the same way asfor adjustment of play when changing motors for axes 5 and 6, see

chapter 5.1, Replacing the motor.

Figure 1 Adjusting the play for the wrist.

Gears on drive shaftunit axes 5 and 6

Upper arm seen from the front

Gears on the wrist



Axes 4-6 (IRB 2400/10/16) Repairs

8. Tighten screws <20> with washer <21> to a torque of 17 Nm.

9. Check the play by moving axes 5 and 6 by hand.



Tightening torque:

Screwed joint of wrist/tubular shaft, item <20>: 17 Nm

5.3 Dismounting the mechanical stop for axis 4


To dismantle:

1. Undo screws <32> and remove the stop for axis 4.

2. Rotate axis 4 so that the damper <30> becomes visible, and pull it out.

To assemble:

3. Mount damper <30>.

4. Put sealing compound Loctite 574 on the stop.

5. Mount stop for axis 4 with screws <32> and tighten with a torque of 15 Nm.

Tightening torque:

Screwed joint of stop/arm housing, item <32>: 15 Nm



Repairs Axes 4-6 (IRB 2400L)

6 Axes 4-6 (IRB 2400L)

6.1 Axis 4

6.1.1 Changing the motor



Position the arm system in such a way that the motor of axis 4 points upwards.

To dismantle:

1. Remove the cover of the motor.





To assemble:


7. Put O-ring <9/18> on the motor.

8. Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector.

9. Install the motor, tighten screws <9/17> to a torque of approximately 2 Nm.

Note the position of the motor

10. Adjust the position of the motor in relation to the drive in the gearbox.

11. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.

12. Make sure there is a small clearance.

13. Unscrew one screw at a time, apply Loctite 242 and tighten to a torque of 4.1 Nm ±10%.


15. Calibrate the robot as in 11, Calibration.



Axes 4-6 (IRB 2400L) Repairs

Tightening torque:

The motor’s fixing screws, item <9/17>: 4.1 Nm ±10%

Tool:

Crank tool for checking the play: 3HAB 1201-1

6.1.2 Changing the intermediate gear including sealing


To dismantle:

1. Dismantle the wrist as in 6.2, The Wrist and Axes 5 and 6.

2. Dismantle the drive mechanism as in6.2.2, Changing the drive shaft unit, gear belts or motors.

3. Dismantle the motor of axis 4 as in 6.1.1, Changing the motor.

4. Remove the cover <28>.

5. Undo screws <12> fixing the large drive gear <10> and dismantle it.

N.B. Put the shims in a safe place.

6. Undo screws <25>.

7. Push the intermediate gear out of the arm housing.

To assemble:

8. Grease the seating of the arm housing to provide radial sealing.

9. Push the gear unit down into the arm housing.

10. Screw in screws <25> together with their washers <24> and pull the gear down.

11. Mount the drive gear <10> using screws <12> and tighten to a torque of 8.3 Nm ±10%.

N.B. Do not forget to insert shims <7, 8, 9> under the drive gear.

12. Tighten screws <25> to a torque of approximately 5 Nm.

13. Bend the pinion towards the large drive gear and then rotate it around the tubularshaft a couple of times so that the clearance in the gears can adjust itself in relationto the highest point of the large drive gear.

14. Then tighten screws <25> to a torque of 20 Nm ±10%.

15. Check the clearance in relation to the tightening torque.






To assemble:

Shim between drive gear <10> and the rear bearing <4>.Shim thickness = B - A + 0.05 mm, see Figure 2.

Figure 2 Measuring the shim thickness of the drive gear of axis 4.

7. Install the drive gear using screws <12> and tighten to a torque of 8.3 Nm ±10%.

N.B. Do not forget the shims.

8. Adjust the intermediate gear as in

6.1.2, Changing the intermediate gear including sealing.

9. Lubricate the drive gear with grease (30 g).

10. Install the motor of axis 4 as in 6.1.1, Changing the motor.

11. Clean the surfaces of the cover. Apply Loctite 574 as sealing

12. Replace the cover <28> using screws <29>. Lock by using a drop of Loctite 242.

13. Mount the drive mechanism as in 6.2.2, Changing the drive shaft unit, gear beltsor motors.

14. Mount the wrist as in 6.2.1, Dismantling the wrist.


Tightening torque:

Screws of drive gear, item <12>: 8.3 Nm ±10%




6.1.4 Changing bearings of the tubular shaft


To dismantle:

1. Dismantle the drive gear as in6.1.3, Changing the drive gear on the tubular shaft.

2. Push out the tubular shaft.

To assemble:

3. Fit a new bearing <4> on the tubular shaft using tool 6896 134-V.

4. Push the tube into the housing of the upper arm.

5. Insert the rear bearing <4> using tool 6896 134-JB.

6. Mount the drive gear as in6.1.3, Changing the drive gear on the tubular shaft.

7. Calibrate the robot as in Chapter 9, Calibration.

Tools:

Pressing tool for front bearing: 6896 134-V

Pressing tool for rear bearing: 6896 134-JB

6.2 The Wrist and Axes 5 and 6

The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units andgears. It is of such a complex design that it is not normally serviced on-site, but shouldbe sent to ABB Flexible Automation to be serviced.

ABB Robotics recommends its customers to carry out only the following servicing andrepair work on the wrist.

• Change the oil according to the table in the chapter on maintenance.




6.2.1 Dismantling the wrist


To dismantle:

1. Remove the 2 plugs on the rear of the wrist.

2. Release the brake in axes 5 and 6.

3. Rotate axes 5 and 6 so that you can see screws <11/9> in the clamping sleevethrough the hole.

4. Disconnect the clamping sleeve.

5. Undo screws <9/37> and washers <9/13>. Remove the wrist.

To assemble:

6. Clean the surface of the tubular shaft.

7. Apply Loctite 574 all around.

8. Mount the wrist, tighten screws <9/37> to a torque of 8.3 Nm ±10%.

9. Screw the clamping sleeves together using screws <11/9> to a torque of 5.7 Nm.

10. Replace the plugs.

11. Mount the cover at the motor side of axis 5-6.


Tightening torque:

Screwed joint of wrist/tubular shaft, item <9/37>: 8.3 Nm ±10%Screwed joint clamping sleeves, item <11/9>: 5.7 Mn ±10%

6.2.2 Changing the drive shaft unit, gear belts or motors


To dismantle:

1. Dismantle the wrist as in section 6.2.1, Dismantling the wrist.

2. Loosen the connection box and disconnect the connectors on the motors of axes 5and 6. Make a note of the motor no. on the motors, to simplify the reconnection.

3. Undo screws <9/14>.




4. Squeeze the drive shafts (<11/1>) together at the tip of the tubular shaft, in orderthat they can pass through the tube.

5. Pull out the complete drive mechanism of axes 5 and 6.

6. Undo screw <11/5> and nuts <11/4>, holding the motors and remove both motors.

7. Undo screw <11/5> and remove the motor plate <11/3> and screw <11/9>.

8. Remove the gear belts.

To assemble:

9. Install the belts <11/7>.

10. Mount the plate <11/3> using screws <11/5> and washers <11/6>.

N.B. Do not forget the nuts on the motors.

11. Install the motors.

12. Push the motors sideways to tighten the belts. Use tool 3HAA 7601-050. Place theround post of the tool into the motor pulley and let the cam press to the outer diam-eter of the large pulley. Tighten screws <11/5> to a torque of 4.1 Nm.

13. Rotate the drive shafts. Check the tension on the belt.

14. Install the drive mechanism in the tubular shaft. Do not forget the rubber damper

<9/11>.

15. Tighten screws <9/14> to a torque of 8.3 Nm.

16. Install the cabling and mount the cover to motors axes 5 and 6.

17. Mount the wrist according to section 6.2.1, Dismantling the wrist.


N.B. It is sufficient to only calibrate axes 5 and 6, if the other axes have been posi-tioned correctly by running the CAL2400 program. Do not forget to change theresolver offset values on the label under the rear cover on the robot base.

Tightening torque:

Screwed joint of the drive mechanism, item <9/14>: 8.3 Nm ±10%Screws holding motors, item <11/5>: 4.1 Nm ±10%




6.2.3 Changing the motor or driving belt of axes 5 and 6


To dismantle:

1. Dismantle the wrist as in section 6.2.1, Dismantling the wrist.

2. Dismantle the drive mechanism as in6.2.2, Changing the drive shaft unit, gear belts or motors.

3. Undo screws <5> and nuts <4>. Remove the appropriate motor.

4. If the driving belt is to be changed, both motors must be removed before plate canbe removed.

5. Undo screws <5> and washers <6>. Remove plate <6>.

To assemble:

6. Install the driving belts.

7. Mount the plate <3> using screws <5> and washers <6>.

N.B. Do not forget the nuts of the motors.

8. Install the motors.

9. Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050.Tighten screws <15> to a torque of 4.1 Nm.

10. Rotate the drive shafts. Check the tension on the belt.

11. Install the drive mechanism as in6.2.2, Changing the drive shaft unit, gear belts or motors.

12. Mount the wrist as in section 6.2.1, Dismantling the wrist.


Tightening torque:

Screws for motors and plate, item <15>: 4.1 Nm.

Tool:

To adjust the belt tension: 3HAA 7601-050



Repairs Push-button unit for brake release

7 Push-button unit for brake release

7.1 General description

See foldout 4.

The push-button unit <121> is located on the flange plate on the base and is used toquickly and safely release the axis brakes manually, when doing various types of workon and around the robot. It is then also possible to move the arms of the robot manually,when this is necessary.

When the controller or certain parts of the cabling have been disconnected, the brakescan be released using a separate 24 VDC power source. The power is connected as

described in one of the following two alternatives:

1. Connector R1.MP on the robot base.+ 24 V to R1.MP. B80 V to C10

Incorrect connections can cause all brakes to be released simultaneously

2. Directly to the cable of the respective brake.The connection must be made in accordance with the wiring diagram for themechanical robot.

Note: when power is connected directly to the brake cable, the brake will bereleased immediately the power is switched on. This can cause some unexpectedrobot movements!

The push-button unit is equipped with six buttons for controlling the axis brakes. Thebuttons are numbered with the axes numbers. The unit is located underneath a rubbercover in the cover. The brakes are of electro-mechanical type and are released when

voltage is applied. To release the brake on a particular axis, push the appropriate buttonand keep it depressed. The brake will function again as soon as the button is released.

0 V C10

NOTE!Be careful not tointerchange the

24 V- and 0 Vpins.In they are mixedup, damage canbe caused to aresistor and thesystem board.

+24 V B8



Push-button unit for brake release Repairs

To dismantle:

See foldout 4.

When replacing the push-button unit <121>, the complete unit should be replaced as fol-

lows:

1. Position the lower arm at one of its end positions and lower the upper arm to its endposition.

Note: the robot must not be in the STANDBY MODE! This applies for all types ofcabling work.

2. Cut the power to the robot by turning off the main switch.

3. Remove the cover.

4. Disconnect the connectors on the cabling to the push-button unit <121>.

5. Remove the push-button unit by undoing the screws.

6. Refit a new unit in the reverse order.



Repairs Cabling and Measuring board

8 Cabling and Measuring board

8.1 Changing serial measuring board


Note!When working with the serial measurement board it is important that a wriststrap is used, to avoid ESD faults.

To dismantle:

1. Remove the flange plate on the base.

2. Cut straps.

3. Unscrew the serial measuring board <115> using nuts <118>.

4. Remove the board and loosen the contacts.

To assemble:

5. Assemble in the reverse order.

8.2 Changing the cabling in axes 1,2 and 3


The cables to motor axes 1, 2 and 3 are handled as one unit.

To dismantle:

1. Remove the cover of the connections boxes.

2. Loosen the flange plate on the base.

3. Loosen connectors R1.MP, R2.FB1-3. Loosen the serial measurement board.

4. Remove cable straps <3/119>. Loosen nuts <5/118>. The lower bracket need notto be removed.

5. Detach the cable guides <3/109>.

6. Loosen covers <3/112> and screws <3/137>. Loosen the connectors.

7. Disconnect the connection boxes in the motors.



Cabling and Measuring board Repairs

8. Loosen screws <3/120>.

9. Feed the cabling up through the middle of axis 1.

To assemble:


8.3 Changing the cabling in axes 4, 5 and 6


The cables to motor axes 4, 5 and 6 and for customer signals are handled as one unit.

To dismantle:

1. Remove the cover of the motors.

2. Loosen the flange plate <3/104>.

3. Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connectorR1.CS, R1.CP and R2.FB4-6, and the air hose in the base. (To reach R2.FB4-6, theserial measurement board can be removed.)

4. Remove cable straps <3/119>. Loosen nuts <5/118>.

5. Loosen screws <3/120> and cable brackets <3/108> between gears 2 and 3 and cutthe tie around them.

6. Feed the cabling and air hose up through axis 1.

7. Loosen the cable bracket on the lower arm and undo screws <3/116>.

8. Loosen connectors R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3FB5 and R3FB6.Loosen the connection box from the motors.

9. Loosen screw <3/137> to remove cable guide <3/111>.

To assemble:


8.4 Changing the signal cabling axis 4, option 04y

To dismantle:

1. Loosen the two plates, two M6 + three M8 screws.



Repairs Cabling and Measuring board

2. Loosen the two holders around the tube shaft.

3. Loosen the connectors at the rear of the upper arm.

To assemble:

4. Apply transparent protection tape on the narrow part of the tube shaft. Remove dirtand grease from the surface first, see Figure 3.

Figure 3 Location of protection tape.

5. Run axis 4 to its calibration position, 0 degrees.

6 Fasten the front (outer) plate with two M6 screws, see Figure 4.

7. Then fasten the rear (inner) plate with three M8 screws, see Figure 4.

Figure 4 Location of screws.

8. Slowly rotate axis 4 clockwise to its stop position. Check all the time that thecables are not fully stretched.

NOTE! If this should happen, stop the rotation and let out more cable from the rearcable holder. This is done by loosening the grey holders and pushing out the cablesby hand.

9. Finish the rotation. NOTE! Leave the rear cable holder open (do not tighten).

Wrist side

Tape

3 M82 M6



Cabling and Measuring board Repairs

10. Mount the front holder around the tube shaft first. Let the black plastic hose aroundthe arm go through the foot of the fixing ring, see Figure 5. Applies to both fixingrings.

Figure 5 Mounting the fixing rings on the tube shaft.

11. Move axis 4 from one extreme limit to the other and back again.

Carefully check the behaviour of the cables! They must not be fully stretched. Thecables and air hose must not touch any moving parts of the arm. The fixing ringsmust be able to slide smoothly the whole time with no excessive pulling.

12. The length of the cables is now finely adjusted by pushing and pulling the cablesthrough the inner holders, which are still loose.

13. When axis 4 is moving, no stretching of the cables should be felt.

14. Tighten the holders by hand. Do not use any tools.

15. Connect the connectors at the rear end of the upper arm.

16. Connect the air hose.

17. Fix the cables and air hose together with cable straps above the motors.



Repairs Motor units

9 Motor units

9.1 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 the respective motor from the cable connectorpoints on the manipulator. The cables are connected to the motor units by connectors.

The drive shaft of the electric motor forms a part of the gearbox of the manipulatoraxis. A brake, operated electromagnetically, is mounted on the rear end of the motorshaft and a pinion is mounted on its drive end. The brake releases when power is sup-plied to the electromagnets.

N.B.There is a feedback device mounted on each motor unit. The device is installed bythe supplier of the motor and should never be removed from the motor.The motor need never be commutated.

The commutation value of the motors is: 1.570800.

The motor, resolver and brakes are regarded as one complete unit, i.e. a replace-ment unit.



Motor units Repairs



Repairs Oil change in gearboxes

10 Oil change in gearboxes

10.1 Oil in gearboxes 1-3 (IRB 2400L/10/16)

ABB article no. 1171 2016-604 corresponds to:

BP: Energol GR-XP 320 Castrol: Alpha SP 320Esso: Spartan EP 320 Klüber: Lamora 320Optimol: Optigear BM 320 Shell: Omala Oil 320Texaco: Meropa 320

Volume of gearbox 1: 6.4 litres (1.7 US gallon)

Volume of gearboxes 2: 4.5 litres (1.3 US gallon)Volume of gearboxes 3: 3.8 litres (1.1 US gallon)

10.2 Oil in gearboxes 4-6 (IRB 2400/10/16)

ABB’s article no. 3HAC 0860-1 corresponds to:

Optimol: Optigear BM 100

Volume of gearbox 4: 1.5 litres (0.4 US gallon)

Volume of gearboxes 5 and 6: 0.8 litres (0.2 US gallon) total

10.3 Oil in gearboxes 4-6 (IRB 2400L)

ABB article no. 1171 2016-604 corresponds to:

BP: Energol GR-XP 320 Castrol: Alpha SP 320Esso: Spartan EP 320 Klüber: Lamora 320Optimol: Optigear 320 Shell: Omala Oil 320Texaco: Meropa 320

Volume of gearbox 4: 30 ml (0.008 US gallon)

Volume of wrist 120 ml (0.032 US gallon)



Oil change in gearboxes Repairs

10.4 Oil plugs, axes 4-6 (IRB 2400/10/16)

The magnetic oil plugs in gearboxes 4, 5 and 6 (see Figure 6) should be cleaned when fillingoil.

Figure 6 Location of oil plugs.

10.5 Oil plugs, axes 5-6 (IRB 2400L)

The magnetic oil plugs in gearboxes 5 and 6 (see Figure 7) should be cleaned when fillingoil.

Figure 7 Location of oil plugs.

10.6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16)

Drain the gearbox:

• Move the arms backwards, and the upper arm at least 45o upwards.

• The oil is drained through the lower drain plug hole at the rear of the upper arm.

New oil is refilled as follows:

• Run the upper arm in a vertical position (rear end upwards).

• The oil is filled through the plug hole.

Oil plug axis 4 Oil plug axes 5 and 6

Oil plug axes 5 and 6



Repairs Oil change in gearboxes

Oil level:

Floor and suspended mounting:

- With the upper arm in a vertical position (rear end upwards) must the oil levelbe min. 32 mm and max. 25 mm from the edge of the upper hole.

Volume:

• 1.5 litre (0.4 US gallon)

10.7 Changing and checking the oil in gearbox 4 (IRB 2400L)

Drain the gearbox:

• Dismantle the motor axis 4, see chapter 6, Changing the motor.

• Run the robot until the upper arm is pointing downward.


• Run the robot until the upper arm is pointing upward.

• The oil is filled through the motor hole.

Volume:

• 30 ml (0.008 US gallon).

10.8 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400/10/16)

Draining the gearbox:

• Run the upper arm to a horizontal position and turn axis 4 to the calibrationposition.

• Remove the oil plugs in the wrist (see Figure 6).

• Turn axis 4 through 90o so that the oil plug on the side of the wrist is pointingdownwards.

• Then turn axis 4 another 90o.

• Let the remaining oil run out through the hole on the tilt housing (axis 5).


• Run the upper arm to a horizontal position and turn axis 4 to the calibrationposition.

• Fill oil in the hole located on the tilt housing (axis 5) until the oil reaches up tothe hole located on the side of the wrist (see Figure 6).

• NOTE! If the robot is mounted in suspension, the wrist should be turned 180o

.• Put the oil plugs back in the wrist.



Oil change in gearboxes Repairs

Oil level:

• Run the robot to the calibration position.

• The oil should be level with the edge of the oil hole on the side.

Volume: (IRB 2400/ 10/16)

• Oil volume for axes 5 and 6 is 0.8 litres (0.2 US gallon).

10.9 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400L)

Draining the gearbox (IRB 2400L):

• Move the upper arm downwards. Both plugs must be off.

New oil is refilled as follows (IRB 2400L):

• Run the upper arm 30° upwards.

• The oil is filled through one of the op en front oil plugs.

• Do not fill oil through the rear two holes.

Volume (IRB 2400L):

• Oil volume for axes 5 and 6 is 0.12 litre (0.03 US gallon).

Oil level (IRB 2400L)

• Run the upper arm 30° upwards. Remove one of the oil plugs in the wrist (turnaxis 6).

• The oil should be level with the edges of the oil hole.



Repairs Calibration

11 Calibration

11.1 General

The robot measurement system consists of one feedback unit for each axis and a meas-urement board which keeps track of the current robot position. The measurement boardmemory is battery-backed.

The measurement system needs to be carefully calibrated (as in 11.2) if any of theresolver values change. Resolver values change when any

- part of the manipulator that affects the calibration position is replaced.

The system needs to be coarsely calibrated (as in 11.3) if the contents of the revolutioncounter memory are lost. The memory may be lost if:

- the battery is discharged

- a resolver error occurs

- the signal between the resolver and measurement board is interrupted.

11.2 Adjustment procedure using calibration equipment (fine calibration)

The axes are calibrated in numerical order, i.e. 1 - 2 - 3 - 4 - 5 - 6.

1. Move the robot to the calibration position, corresponding to the calibration marks,as shown in Figure 19.

2. Calibrate all the axes as described below.

3. Press the Misc. window key (see Figure 8).

Figure 8 The Misc. window key.

4. Choose Service from the dialog box that appears on the display.

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2



Calibration Repairs

5. Press Enter .

6. Choose View: Calibration. The window shown in Figure 9 appears.

Figure 9 The window shows whether or not the robot system units are calibrated.

The calibration status can be any of the following:

- SynchronizedAll axes are calibrated and their positions are known. The unit is ready for use.

- Not updated Rev. CounterAll axes are fine-calibrated but the counter on one (or more) of the axes isNOT updated. Therefore, this axis or axes must be updated as described in

11.3.- Not calibrated

One (or more) of the axes is NOT fine-calibrated. Therefore, this axis or axesmust be fine-calibrated as described in 11.2.

7. If there is more than one unit, select the desired unit in the window in Figure 9.Choose Calib: Calibrate and the window shown in Figure 10 will appear..

Figure 10 The dialog box used to calibrate the manipulator.


1(4)

Service Calibration

Mech Unit Status

Robot Not Calibrated

Incl All Cancel OK

1(6)

Calibration!

Robot

To calibrate, include axes and press OK.

Axis Status

X 1 Not Fine Calibrated


3 Fine Calibrated

4 Fine Calibrated





Repairs Calibration

8. Press the function key All to select all axes, if all axes are to be calibrated. Otherwise, select the desired axis and press the function key Incl (the selected axis

is marked with an x).

9. Confirm your choice by pressing OK . The window shown in Figure 11 appears.

Figure 11 The dialog box used to start the calibration.

10. Start the calibration by pressing OK .

An alert box is displayed during the calibration.The Status window appears when the fine calibration is complete. The revolutioncounters are always updated at the same time as the calibration is performed.

The robot is now roughly calibrated.

11. Remove the protective plate from the reference surface on the manipulator base.

12. Attach the calibration tool for axis 1 on the guide pin underneath the gearbox, seeFigure 12.

Figure 12 Calibration of axis 1.

Cancel OK

Calibration!

Robot

- - - - - WARNING - - - - -

The calibration for all marked axes

will be changed.


OK to continue?

Tool no.3HAB 8064-1

Guide pin



Calibration Repairs

13. Release the brakes and move the manipulator manually and fix the tool to the basewith the screw. NOTE! Do not tighten the screw.

14. Then move the manipulator so that the pin in the tool can be located in the guidehole in the base.

15. Update axis 1 only, as described above.

16. Remove the calibration tool for axis 1.

17. Fit the reference plane no. 6808 0011-GM on the foot.

18. Calibrate the sensors against each other, using the reference plane surface. See Fig-ure 13. The sensors must be calibrated every time they are used for a new direction.

Figure 13 Calibrating the sensors.

19. Fit the angle shelf no. 6808 0011-LP on the lower arm. Adjust the angle of theshelf, with the help of the sensors, before starting calibration.

20. Fit the angle shelf no. 6808 0011-GU + sync. adapter no. 3HAB 7981-1 + pin onthe turning disc. Dont use synchronous adapter on IRB 2400L.

21. Position the sensors as shown Figure 14, for axis 2.

22. Run the manipulator so that the instrument shows 0 ±16 increments (0.4 mm/m).

23. Update axis 2 as described above. Remove the sensors.

24. Select the Program window and open the file CAL2410 on the Controller Param-eter disk. Run the program and select Calib: Cal3. The robot will now move itselfto the position for calibration of axis 3.

25. Put the sensors on the shelf and jog the robot to the calibration position,0±16 increments. See Figure 14.

26. Update axis 3, as described above. Remove the sensors.

27. Run the calibration program 4A on the system diskette.

28. Calibrate the sensors for a new direction. See Figure 13.

0000Reference plane

Level sensors

Calibrating sensorsfor axes 2, 3 and 5

Calibrating sensorsfor axes 4 and 6



Repairs Calibration

29. Run axis 4 to the correct position as indicated by the instrument, 0 ±32 increments.

30. Update axis 4 as described above. Remove the sensors.

31. Run the calibration program 4B.

32. The robot will now be standing in the correct position.

33. Update axis 4 as described above.


35. Put the sensors on the shelf and run the robot so that axis 5 comes to the correctcalibration position, 0 ±32 increments. See Figure 14.



38. Adjust axis 6, 0 ±32 increments. See Figure 14.


40. Save system parameters on a floppy disk.

41. Change the values on the label, located underneath the flange plate on the base (seeFigure 14).



Calibration Repairs

Figure 14 Calibration directions.

Calibration plate and calibration marks

42. The calibration positions for axes 1, 2, 3, 4 and 6 are marked using a punch marktool, see Figure 19.

43. Check the calibration position as specified in 11.4.

Axis 2

Axis 5

Axis 6

View fromabove

Flange plate

Axes 2, 3 and 5

Axes 4 and 6

Upper arm seen from above

Axis 3

Axis 4



Repairs Calibration

11.3 Setting the calibration marks on the manipulator

When starting up a new robot, a message may be displayed telling you that the manip-ulator is not synchronised. The message appears in the form of an error code on theteach pendant. If you receive such a message, the revolution counter of the manipulatormust be updated using the calibration marks on the manipulator. See Figure 19.

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 hasbeen interrupted

- when one of the manipulator axes has been manually moved without the con-

troller being connected.

It takes 36 hours in Power On mode without any power interruption to recharge thebattery unit.

If the resolver values must be calibrated, this should be done according to 11.2.

WARNING Working in the robot work cell is dangerous.

Press the enabling device on the teach pendant and, using the joystick, manually movethe robot so that the calibration marks lie within the tolerance zone (see Figure 19).N.B.! Axes 5 and 6 must be positioned together.

When all axes have been positioned as above, the values of the revolution counter canbe stored by entering the following commands on the teach pendant:

1. Press the Misc. window key (see Figure 15).

Figure 15 The Misc. window key from which the Service window can be chosen.

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2



Calibration 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 16 appears.

Figure 16 This window shows whether or not the robot system units are calibrated.

5. Select the desired unit in the window, as in Figure 16.Choose Calib: Rev. Counter Update. The window shown in Figure 17 appears.

Figure 17 The dialog box used to select the axes for which the revolution counter must beupdated.

6. 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 markedwith an x).

Robot Unsynchronized


1(4)

Service Calibration

Mech Unit Status



3 Calibrated

4 Calibrated



Incl All Cancel OK

1(6)

Rev. Counter Updating!Robot

To update, include axes and press OK.

Axis Status



Repairs Calibration

7. Confirm by pressing OK . A window similar to the one in Figure 18 appears.

Figure 18 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.Thus, check the calibration very carefully after each update. Incorrect updatingcan damage the robot system or injure someone.

9. Check the calibration as described in 11.4.

10. Save system parametrs on a floppy disk.

Cancel OK

Rev. Counter Updating!

Robot

The Rev. Counter for all marked axes

will be changed.


OK to continue?



Calibration Repairs

Figure 19 Calibration marks on the manipulator.

IRB 2400/10IRB 2400/16

IRB 2400L

Punch, axis 63HAB 8184-1





2 markings




Punch, axis 23HAB 8223-12 markings




Repairs Calibration

11.4 Checking the calibration position

There are two ways to check the calibration position; both are described below.

Using the diskette, Controller Parameters:

Run the program \ SERVICE \ CALIBRAT \ CAL 1400 (or 1400H) on the diskette, fol-low intructions displayed on the teach pendant. When the robot stops, switch toMOTORS OFF. Check that the calibration marks for each axis are at the same level,see Figure 19. 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 cal-

ibration marks for each axis are at the same level, see Figure 19. If they are not, thesetting of the revolution counters must be repeated.

11.5 Alternative calibration positions

The robot must have been calibrated with calibration equipment at calibration position0 for all axes (the robot is delivered with calibration position 0), see Figure 20, beforeit can be calibrated in one of the alternative positions.

Figure 20 Calibration positions

Axis 1 2 3

Calibration prog. Normal Hanging

Cal pos 0 - 1.570796 - 1.570796

Axis 1 2 3

Calibration prog. Normal Normal

Cal pos 0 0 0



Calibration Repairs

Note!If the final installation makes it impossible to reach the calibration 0 position, an alter-native calibration position can be set before installation.

1. Run the calibration program CAL2410 on the Controller Parameter disk. SelectCal.post Normal + Normal position, check the calibration marks for each axes.

2. Run the calibration program again and select the desired calibration position, seeFigure 20.

3. Change to the new calibration offset for the axis in question, as follows:

• Select the window SERVICE;

• View: Calibration;

• Calib: Calibrate;

• Select axis

• Then confirm by pressing OK twice.

4. Change to the new calibration offset on the label, located under the cover on the backof the foot. The new calibration offset values can be found as follows:

• Select the window SYSTEM PARAMETERS;

• Manipulator

• Types: Motor;

• Select axis 1;

• Press Enter

• Note the Cal offset value.

• Do the same for axis 3.

5. Change to the new calibration position on the axes that have been changed, as fol-lows:

• Select the window SYSTEM PARAMETERS;

• Topics: Manipulator;

• Types: Arm;

• Select axes;

• Change Cal pos to the value showed in Figure 20. The angle is in radians.

6. Update the revolution counters for axes 2 and 3.

7. Restart the robot by selecting File: Restart.

8. Save the system parameters on a floppy disk



Repairs Calibration

11.6 Calibration equipment

For calibration:

Axis 1 3HAB 8064-1Axis 2 6808 0011-LPAxis 3-6 6808 0011-GU

3HAB 7981-1 (only 2400/10 and /16)2111 2021-399

Reference 6808 0011-GMLevel indicator 6807 081-D

Marking equipment:

Axis 1-4 3HAB 8223-1

Axis 6 3HAB 8184-1

11.7 Operating the robot

How to start and operate the robot is described in the User’s Guide. Before start-up,make sure that the robot cannot collide with other objects in the working space.



Calibration Repairs



Spare Parts

CONTENTSPage

1 Manipulator ............................................................................................................. 2

1.1 Manipulator.....................................................................................................2

1.2 Upper arm parts, axes 4-6 (IRB 2400/10/16)..................................................5

1.3 Upper arm parts, axes 4-6 (IRB 2400L) .........................................................7

1.4 Drive unit, axes 5-6 (IRB 2400L)...................................................................9

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Spare Parts

Spare Parts

1 Manipulator

Item number refers to item number on the foldouts.

1.1 Manipulator

Itm Qty Name Art. no Rem

1 1 Foot 3HAB 9348-1

2 1 Gear box axes 1-3 3HAC 4795-13 12 Hex socket head cap screw 3HAB 3402-69 M12x50 8.8

Gleitmo 610

4 12 Plain washer 9ADA 312-9 13x24x2.5

5 2 Motor axes 1 and 3 3HAC 4789-1

6 3 O-ring 2152 2012-434 109.5x3

7 12 Spring washer 2154 2033-9 8.4x18x2

8 4 Hex socket head cap screw 3HAB 3409-45 M8x65 12.9Gleitmo 610


10 1 Lower arm 3HAC 4796-1 2400/10, /161 Lower arm 3HAC 4797-1 2400L

11 8 Spring washer 2154 2033-10 10.5x23x2.5


13 1 Spring tension plate 3HAC 2205-1 66x116x3

14 1 Damper, standard axis 2 3HAC 2180-1

15 1 Damper axis 3 3HAB 5512-1

16 4 Torx pan head roll. screw 9ADA 629-56 M6x16


18 1 Parallel arm 3HAB 9394-1

19 2 Sealing ring 3HAB 3732-13 V-110-L 99x10.5

20 1 Groove ball bearing 3HAB 3643-12 61822-2RS1

21 2 Sealing ring 3HAB 5515-1 Acetal (POM)

26 2 Hex socket head cap screw 9ADA 183-34 M8x12

33 1 Locking washer 3HAB 5523-1 SS 1914-04

34 1 Hex socket counters, head 2121 2852-449 M8x16 8.8

35 1 Back-up ring 3HAB 5510-1 Acetal (POM)





Spare Parts

36 1 Motor axis 2 3HAC 4790-1

41 Lubricating oil 1171 2016-604 14 700 ml

42 Bearing grease 3HAB 3537-1 1 g

43 Locking liquid 3HAB 7116-1 1 ml Loctite 243

46 1 Stop axis 1 3HAB 6687-1

48 6 Washer 2151 2082-150 6.1x20x2

49 1 Friction washer 3HAC 0447-1

50 1 Sync. mark. axis 2 3HAB 5522-1

51 1 Upper arm axis 4-6 See 1.2 and 1.3

54 2 Lock nut 2126 2851-107 M35x1.5

55 2 Shaft end 3HAB 5527-1 SS 1672-08

56 2 Hex socket head cap screw 3HAB 7700-71 M12x60 12.9Unbrako

Gleitmo 610

57 2 VK-cover 3HAA 2166-15 VK 62x8

60 1 Sync. market axis 3 3HAB 8385-1

62 2 Washer 3HAA 1001-134

63 9 Torx pan head roll screw 9ADA 629-43

100 1 Cable unit axes 1-3 3HAC 4791-1

102 1 Bottom plate 3HAC 2828-1

103 1 Gasket 3HAB 7446-1

104 1 Cover 3HAC 9368-1 Ext. con. (Standar

104 1 Cover 3HAC 9362-1 Int. con. (Foundry

105 1 Gasket 3HAB 5537-1

106 1 Sealing 3HAB 5922-1

107 1 Bracket 3HAB 5923-1

108 2 Holder for cable guide 3HAB 3299-1

109 1 Cable guide 3HAB 5924-1

110 1 Spring 3HAB 3662-1

111 1 Cable guide upper arm 3HAB 5928-1 IRB 2400/10/16

111 1 Cable guide upper arm 3HAB 5928-1 IRB 2400L

112 3 Cover 3HAB 7383-1

114 1 Instruction plate 3HAC 2589-1

115 1 Serial meas. board 3HAB 3700-1


117 1 Battery unit 4944 026-4

118 14 Hexagon nut with flange 9ADA 290-1 M5 fzb

119 12 Cable straps, outdoor 2166 2055-3 L=208 mm

121 1 Push button unit 3HAC 0017-1

122 4 Distance bolt 2125 2052-198 M5x15123 1 Push button cover 3HAC 2744-1





Spare Parts

125 1 Cable straps, outdoors 2166 2055-7 8.9x780

127 1 Gasket 3HAB 7195-1 Int. connections

129 1 Signal cable SMB 3HAB 3774-1 Ext. connections

130 4 Torx pan head roll. screw 9ADA 629-22 M3x6 Ext. conn.

131 1 Gasket 5217 649-64 Ext. connections132 2 Dust cap 3HAC 7561-3

133 1 Dust cap 3HAC 7561-4

134 15 Torx pan head screw 9ADA 618-56 M6x16 8.8

135 3 Hex socket head pan screw 9ADA 183-34 M8x12 8.8

136 8 Torx pan head roll. screw 9ADA 629-34 M4x12 Ext. conn


138 6 Cable straps, outdoors 2166 2055-1 L=101 mm

139 1 Coupling 3HAB 3333-20

140 Locking liquid 1269 0014-412 Loctite 542141 2 Protective hood 2522 2101-8 D=11.4 - 13

147 3 Gasket 3HAB 3676-1

149 1 Gasket 3HAB 7160-1

150 Flange sealing 1234 0011-116 Loctite 574

151 Adhesive tape 1169 9198-301 19x0.18

152 1 Bracket 3HAB 5921-1

156 1 Parallel pin 3HAC 3785-1

157 1 Adaptor, customer cabling 3HAB 7328-1

157 1 Cover protection 3HAC 6823-1

158 1 Adaptor, power cabling 3HAB 2809-1

159 2 Protection cover 3HAC 7816-1 Foundry

160 1 Sealing 3HAC 5479-3

161 1 Sealing 3HAC 5479-4

162 2 Housing (40p) protection 3HAC 6411-1 Foundry

165 1 Designation sign 3HAB 8431-1

168 1 Protective hood 3HAC 3189-1 Suspended

169 2 Gasket 3HAB 9040-1

170 1 Cover 3HAC 0048-1

171 Profile 1866 1903-1 120 mm

172 1 Washer 3HAC8976-1

























Spare Parts

1.2 Upper arm parts, axes 4-6 (IRB 2400/10/16)


1 1 Upper arm without wristand motors 3HAC 1581-1

13 4 Disc spring 3HAB 3731-14 67.5x50.5x0.7

18 1 Wrist 3HAB 9439-1 Std.18 1 Wrist 3HAB 9398-1 Foundry

19 1 O-ring 3HAB 3772-12 Nitrile rubber 126


21 15 Plain washer 9ADA 312-7 8.4x16x1.6

25 1 Motor unit axis 5 3HAB 9440-1 10 kg

1 Motor unit axis 5 3HAB 9442-1 16 kg

26 2 Motor unit axes 4 3HAB 9443-1

27 3 O-ring 3HAB 3772-1 Nitrile rubber 34.

28 12 Plain washer 9ADA 312-6 6.4x12x1.6




33 Lubricating oil 3HAC 0860-1 2300 ml

34 2 Magnetic plug 2522 122-1 R1/4”35 2 Sealing ring 2152 2031-6

39 Bearing grease 3HAB 3537-1 50 g

40 Flange sealing 1234 0011-116 30 ml, Loctite 574

41 2 Sealing ring without dust lip 3HAC 7877-2

42 2 Taper roller bearing 3HAA 2103-15 32007 X

43 1 Parallel bar 3HAC 1564-1

44 2 Spherical roller bearing 3HAA 2167-12 22206 CC

45 2 Sealing ring without dust lip 3HAC 3990-14 Nitrile rubber


47 1 Bracket 3HAC 0001-1

48 1 Backup ring 3HAB 5510-1

49 1 Hex socket counters, head 2121 2852-449 M8x16 8.8

50 1 Locking washer 3HAB 5523-1 SS 1914-04

51 Locking liquid 3HAB 7116-1 6 ml, Loctite 243

52 3 Gasket 3HAC 4429-1


54 9 Torx pan head screw 9ADA 618-46 M5x20 8.8

55 9 Cable straps, outdoors 2166 2055-1 2.5x101

56 Adhesive tape 1169 9198-301 500 mm, 19x0.18

57 1 Cover 3HAB 6491-1





Spare Parts

57 1 Cover with lamp unit 3HAC 2774-1


59 2 Hex socket head cap screw 9ADA 183-22 M6x10

1 Customer cable extension, 3HAB 8869-1 Option 043axis 4 See below

61 1 Washer 3HAC 8976-1

62 1 Motor unit axis 6 3HAB 9443-2













Spare Parts

1.3 Upper arm parts, axes 4-6 (IRB 2400L)


1 1 Tubular shaft 3HAC 0235-12 1 Back-up ring 3HAB 6354-1

3 1 Sealing ring 3HAB 3732-13 99x10.5V-110-L

4 2 Ball bearing 2213 253-12 105x130x1361821-2RSI

5 2 Cover plug 2216 264-14 IRB 2000

6 1 Housing, axis 4 3HAC 0236-17 2 Spacer 2159 167-61 D=115/105, T=0.0

8 4 Spacer 2159 167-62 D=115/105, T=0.1

9 1 Spacer 2159 167-63 D=115/105, T=0.510 1 Gear, axis 4, step 2 3HAB 3210-1

11 1 Damper, axis 4 3HAB 6356-1


13 10 Plain washer 9ADA 312-6 6.4x12x1.6A2F


15 1 Drive unit axis 5-6 See 1.4

16 1 Motor unit, axis 4 3HAC 0238-117 4 Hex socket head cap screw 9ADA 183-14 M5x16 8.8

A2F

18 1 O-ring 2152 2011-414 44.2x3Nitrile rubber

23 1 Gear unit, axis 4 3HAB 3380-1

24 2 Plain washer 9ADA 312-7 8.4x16x1.6A2F

25 2 Hex socket head cap screw 9ADA 183-38 M8x30 8.8A2F

28 1 Cover 3HAB 6355-1

30 Lubricating oil 1171 2016-604 30 ml

31 Locking liquid 3HAB 7116-1 Loctite 243

32 Locking liquid 1269 0014-413 Loctite 638

34 Flange sealing 1234 0011-116 Loctite 574

35 Bearing grease 3HAB 3537-1 Shell Retinax MS

36 1 Wrist, 5 kg 3HAC 0242-1 Std.36 1 Wrist, 5 kg 3HAC 0243-1 Foundry




Spare Parts

38 1 Cover 3HAB 4350-11 Cover with lamp unit 3HAC 2743-1

39 39 Torx pan head roll screw 9ADA 629-44 M5x12 8

40 1 Cover 3HAB 4405-1

42 1 Gasket 3HAB 7387-143 2 Sealing ring (without dust lip) 3HAB 7877-2 D=42/55 W=8

Nitrile rubber

44 2 Taper roller bearing 3HAA 2103-15 D=35/62 W=1832007 X

45 10 Cable straps, outdoors 2166 2055-1 2.5x101Polyamide 6.6 bla

46 1 Clamp 2166 2018-8 D=65562-00-04

47 1 Clamp 2166 2018-2 D=115562-00-07

48 1 Bracket, axes 5-6 3HAB 3230-1

49 2 Torx pan head roll screw 9ADA 629-47 M5x25 8A2F

50 1 Parallel bar 3HAC 1563-1

51 1 Damper, axis 3 3HAB 5511-1

52 2 Hex socket head cap screw 9ADA 183-22 M6x10 8.8A2F

53 2 Spherical roller bearing 3HAA 2167-12 D=30/62 W=2022206 CC

54 2 Sealing ring (without dust lip) 3HAB 3990-14 D=40/62 W=7

Nitrile rubber55 1 Backup ring 3HAB 5510-1 30.1x6

Acetal (POM) bla

56 1 Locking washer 3HAA 2356-11 9x35x357 1 Hex socket head cap screw 3HAB 3402-36 M8x20 8.8

Gleitmo 610

58 1 Cable bracket upper arm 3HAB 5927-1


60 3 Gasket 3HAB 4429-1

61 1 Cable straps, outdoors 2166 2055-3

62 2 Washer 3HAC 8976-1 Foundry











Spare Parts

1.4 Drive unit, axes 5-6 (IRB 2400L)


1 1 Drive shaft unit, axes 5-6 3HAC 0240-1

2 2 Motor unit axes 5-6 3HAC 0241-1

3 1 Motor plate 3HAA 2504-1

4 8 Hexagon nut 9ADA 267-5 M5 8A2F


6 10 Plain washer 9ADA 312-5 5.3x10x1A2F

7 2 Gear belt 3HAA 2393-1

9 2 Hex socket head cap screw 3HAB 3404-14 M5x16Gleitmo 610 10.9









Manipulator Circuit Diagram

Product Manual IRB 2400 M2000

LIST OF CONTENTS







CONNECTION POINT LOCATIONS







BREAK UNIT







MOTOR AXIS 1 - 3







SERIAL MEASUREMENT BOARD







MOTOR AXIS 4 - 6, 1.5 - 10 / 16







FEED- BACK AXIS 4 - 6, 1.5 10 / 16







MOTOR AXIS 4 - 6, 1.8 - 5







FEED - BACK AXIS 4 - 6, 1.8 - 5







CUSTOMER CONNECTIONS







INTEGRATED WIREFEED CABLING (OPTION)







POS. INDICATOR AXIS 1 (OPTION)



Date post:	03-Jun-2018
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