Robot ABB IRB6600 M - A Electrical Maintenance Training Manual

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Product Manual Industrial Robot IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6600 - 175/2.55 IRB 6650 - 200/2.75 IRB 6650 - 125/3.2 M2000A



Product Specification 3HAC 14064-1/M2000/Rev 2 IRB 6600 - 175/2.55 IRB 6600 - 225/2.55 IRB 6600 - 175/2.8 IRB 6650 - 125/3.2 IRB 6650 - 200/2.75

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

© Copyright 2001 ABB. All rights reserved. Article number: 3HAC 14064-1 Issue: M2000/Rev. 2 ABB Automation Technology Products AB Robotics SE-721 68 Västerås Sweden

Product Specification IRB 6600 CONTENTS Page 1 Description ....................................................................................................................... 3 1.1 Structure.................................................................................................................. 3 Different robot versions ......................................................................................... 4 Definition of version designation........................................................................... 4 1.2 Safety/Standards ..................................................................................................... 6 1.3 Installation .............................................................................................................. 10 External Mains Transformer .................................................................................. 10 Operating requirements.......................................................................................... 10 Mounting the manipulator...................................................................................... 10 1.4 Load diagrams ........................................................................................................ 13 Maximum load and moment of inertia for full and limited axis 5 (centre line down) movement......................................................................... 24 Mounting equipment .............................................................................................. 25 Holes for mounting extra equipment ..................................................................... 26 1.5 Maintenance and Troubleshooting ......................................................................... 30 1.6 Robot Motion.......................................................................................................... 31 Performance according to ISO 9283...................................................................... 34 Velocity .................................................................................................................. 34 1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 34 1.8 SpotPack and DressPack ........................................................................................ 35 Description of DressPack....................................................................................... 37 Description of Water and Air unit.......................................................................... 39 Description of Power Unit ..................................................................................... 40 1.9 Description of Variants and Options for SpotPack................................................. 41 1.10 Examples of SpotPacks ........................................................................................ 59 1.11 Servo Gun (option) ............................................................................................... 62 1.12 Track Motion ........................................................................................................ 68 2 Specification of Variants and Options........................................................................... 69 3 Accessories ....................................................................................................................... 79 4 Index ................................................................................................................................. 81

Product Specification IRB 6600 M2000

1

Product Specification IRB 6600

2

Product Specification IRB 6600 M2000

Description

1 Description 1.1 Structure A new world of possibilities opens up with ABB’s IRB 6600 robot family. It comes in five versions, 175kg /2.55m, 225kg /2.55 m, 175kg /2.8m, 125kg/3.2m, and 200kg/2.75m handling capacities. The IRB 6600 is ideal for process applications, regardless of industry. Typical areas can be spotwelding, material handling and machine tending. We have added a range of software products - all falling under the umbrella designation of Active Safety - to protect not only personnel in the unlikely event of an accident, but also robot tools, peripheral equipment and the robot itself. The robot is equipped with the operating system BaseWare OS. BaseWare OS controls every aspect of the robot, like motion control, development and execution of application programs, communication etc. See Product Specification S4Cplus. For additional functionality, the robot can be equipped with optional software for application support - for example spot welding, communication features - network communication - and advanced functions such as multi-tasking, sensor control, etc. For a complete description on optional software, see the Product Specification RobotWare Options.

Axis 3 Axis 4 Axis 5

Axis 6

Axis 2

Axis 1

Figure 1 The IRB 6600 manipulators have 6 axes.

Product Specification IRB 6600 M2000

3

Description Different robot versions The IRB 6600 is available in five versions. The following different robot types are available: Standard: IRB 6600 - 175 kg / 2.55 m IRB 6600 - 225 kg / 2.55 m IRB 6600 - 175 kg / 2.8 m IRB 6650 - 125 kg / 3.2 m IRB 6650 - 200 kg / 2.75 m Definition of version designation IRB 6600 Mounting - Handling capacity / Reach

Prefix Mounting

-

Description Floor-mounted manipulator

Handling capacity

yyy

Indicates the maximum handling capacity (kg)

Reach

x.x

Indicates the maximum reach at wrist centre (m)

Manipulator weight

IRB 6600-175/2,55 IRB 6600-225/2,55 IRB 6600-175/2,8 IRB 6650-125/3.2 IRB 6650-200/2.75

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

1700 kg 1700 kg 1700 kg 1725 kg 1700 kg < 73 dB (A) Leq (acc. to Machinery directive 98/37/EEC)

Power consumption at max load: ISO Cube: 2.6 kW Normal robot movements: 3.8 kW

4

Product Specification IRB 6600 M2000

Description

1142 IRB 6600-2,55 ; IRB 6650-2.75 1392 IRB 6600-2,8 1592 IRB 6650-3.2

IRB 6600 2445 IRB 6650

2240 IRB 6600

1280 IRB 6650

6600-400/2.55

R 580 R 690 with fork lift

Figure 2 View of the manipulator from the side and above (dimensions in mm). Allow 200 mm behind the manipulator foot for cables.

Product Specification IRB 6600 M2000

5

Description

1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.06/1999 Industrial robots, safety requirements ISO 9787 Manipulating industrial robots, coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC, Generic emission EN 61000-6-2 EMC, Generic immunity ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General Safety Requirements The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. The Service Information System (SIS) The service information system gathers information about the robot’s usage and by that determines how hard the robot has been used. The usage is characterised by the speed, the rotation angles and the load of every axis. With this data collection, the service interval of every individual robot of this generation can be predicted, optimising and planning ahead service activities. The collection data is available via the teach pendant or the network link to the robot. The Process Robot Generation is designed with absolute safety in mind. It is dedicated to actively or passively avoid collisions and offers the highest level of safety to the operators and the machines as well as the surrounding and attached equipment. These features are presented in the active and passive safety system. The Active Safety System The active safety system includes those software features that maintain the accuracy of the robot’s path and those that actively avoid collisions which can occur if the robot leaves the programmed path accidentally or if an obstacle is put into the robot’s path. The Active Brake System (ABS) All robots run with an active brake system that supports the robots to maintain the programmed path even in an emergency situation. 6

Product Specification IRB 6600 M2000

Description The ABS is active during all stop modes, braking the robot to a stop with the power of the servo drive system along the programmed path. After a specific time the mechanical brakes are activated ensuring a safe stop even in case of a failure of the drive system or a power interruption. The maximal applicable torque on the most loaded axis determines the stopping distance. The stopping process is in accordance with a class 1 stop. While programming the robot in manual mode a class 0 stop, with mechanical brakes only, applies. The Self Tuning Performance (STP) The Process Robot Generation is designed to run at different load configurations, many of which occur within the same program and cycle. The robot’s installed electrical power can thus be exploited to lift heavy loads, create a high axis force or accelerate quickly without changing the configuration of the robot. Consequently the robot can run in a “power mode” or a “speed mode” which can be measured in the respective cycle time of one and the same program but with different tool loads. This feature is based on QuickMoveTM. The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools like RobotStudio. The Electronically Stabilised Path (ESP) The load and inertia of the tool have a significant effect on the path performance of a robot. The Process Robot Generation is equipped with a system to electronically stabilise the robot’s path in order to achieve the best path performance. This has an influence while accelerating and braking and consequently stabilises the path during all motion operations with a compromise of the best cycle time. This feature is secured through TrueMoveTM. Over-speed protection The speed of the robot is monitored by two independent computers. Restricting the working space The movement of each axis can be restricted using software limits. As options there are safeguarded space stops for connection of position switches to restrict the working space for the axes 1-3. Axes 1-3 can also be restricted by means of mechanical stops. Collision detection (option) In case an unexpected mechanical disturbance occurs, like a collision, electrode sticking, etc., the robot will detect the collision, stop on the path and slightly back off from its stop position, releasing tension in the tool. The Passive Safety System The Process Robot Generation has a dedicated passive safety system that by hardware construction and dedicated solutions is designed to avoid collisions with surrounding equipment. It integrates the robot system into the surrounding equipment safely. Compact robot arm design The shape of the lower and upper arm system is compact, avoiding interference into the working envelope of the robot. Product Specification IRB 6600 M2000

7

Description The lower arm is shaped inward, giving more space under the upper arm to re-orientate large parts and leaving more working space while reaching over equipment in front of the robot. The rear side of the upper arm is compact, with no components projecting over the edge of the robot base even when the robot is moved into the home position. Moveable mechanical limitation of main axes (option) All main axes can be equipped with moveable mechanical stops, limiting the working range of every axis individually. The mechanical stops are designed to withstand a collision even under full load. Position switches on main axes (option) All main axes can be equipped with position switches. The double circuitry to the cam switches is designed to offer personal safety according to the respective standards. The Internal Safety Concept The internal safety concept of the Process Robot Generation is based on a two-channel circuit that is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot. Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate. Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. Safeguarded space stop The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. 8

Product Specification IRB 6600 M2000

Description Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program stop with no deviation from the programmed path. After approx. 1 second the power supplied to the motors is shut off. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the button is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety. Safety lamp (option) As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.

Product Specification IRB 6600 M2000

9

Description 1.3 Installation All versions of IRB 6600 are designed for floor mounting. Depending on the robot version, an end effector with max. weight of 175 to 225 kg including payload, can be mounted on the mounting flange (axis 6). See Load diagram for IRB 6600 generation robots on page 14, page 16, page 18, page 20 and page 22. Extra loads (valve packages, transformers) can be mounted on the upper arm with a maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted on the frame of axis 1. Holes for mounting extra equipment on page 26. The working range of axes 1-3 can be limited by mechanical stops. Position switches can be supplied on axes 1-3 for position indication of the manipulator. External Mains Transformer The robot system requires a 400 - 475 VAC power supply. Therefore an external transformer will be included when a mains voltage other than 400-475V is selected. Operating requirements Protection standards Standard and Foundry Manipulator

IP67

Cleanroom standards Cleanroom class 100 for manipulator according to: • DIN EN ISO 14644: Cleanrooms and associated controlled environments • US Federal Standard 209 e - Air-clean-classes Explosive environments The robot must not be located or operated in an explosive environment. Ambient temperature Manipulator during operation For the controller: standard option

+5oC (41oF) to +50oC (122oF) +45oC (113oF) +52oC (126oF)

Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF) for short periods (not exceeding 24 hours) up to +70oC (158oF) Relative humidity Complete robot during transportation and storage Max. 95% at constant temperature Complete robot during operation Max. 95% at constant temperature Mounting the manipulator Maximum load in relation to the base coordinate system.

Force xy Force z Torque xy Torque z 10

Endurance load in operation

Max. load at emergency stop

±10.1 kN 18.0 ±13.8 kN

±20.7 kN 18.0 ±22.4 kN

±27.6 kNm ±7.4 kNm

±50.6 kNm ±14.4 kNm Product Specification IRB 6600 M2000

88 ± 0.3

Description

Recommended screws for fastening the manipulator to a base plate: M24 x 120 8.8 with 4 mm flat washer Torque value 775 Nm

Figure 3 Hole configuration (dimensions in mm).

Product Specification IRB 6600 M2000

11

Description

B D 5

325

B

37,5 o

A

C

15

o

A

C o

10

50 522

1

A

0.1 A

A-A

1.5

B-B

C-C

D Two guiding pins required, dimensions see Figure 5

Figure 4 Option Base plate (dimensions in mm).

12

Product Specification IRB 6600 M2000

Description

Protected from corrosion Figure 5 Guide sleeve (dimensions in mm)

1.4 Load diagrams The load diagrams include a nominal payload inertia, J0 of 15 kgm2, and an extra load of 50 kg at the upper arm housing, see Figure 6. At different arm load, payload and moment of inertia, the load diagram will be changed. For an accurate load diagram, please use the calculation program, ABBLoad for 6600 on: • inside.abb.com/atrm, click on Products --> Robots --> IRB 6600 or • http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB 6600. Centre of gravity 50 kg 400

200

Figure 6 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).

Product Specification IRB 6600 M2000

13

Description Load diagram for IRB 6600-175/2.55

0,80

80 kg 0,70

100 kg

0,60

120 kg

Z-distance (m)

0,50

135 kg 0,40

150 kg

175 kg 0,30

180 kg 185 kg

0,20

200 mm

0,10

0,00 0,00

0,10 0,10

0,20

0,30

0,40

0,50

L-distance (m )

Figure 7 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity).

14

Product Specification IRB 6600 M2000

Description Load diagram for IRB 6600-175/2.55 “Vertical Wrist” (±10o)

L

“Vertical wrist”

Load diagram "Vertical Wrist" (±10°)

10o 10o

IRB 6600 - 175/2.55 Armload: 50kg

Z

200 mm

L-distance (m) 0,0

0,2 0,20

0,4 0,40

0,6 0,60

Pay load

0,8 0,80

1,0 1,00

1,2 1,20

1,4 1,40

0,0

0,20 0,2 210 kg 190 kg 0,40 0,4

Z-distance (m)

150 kg 0,60 0,6 100 kg 0,80 0,8 75 kg 1,00 1,0

1,20 1,2

1,40 1,4

Figure 8 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist” (±10o), J0 =15 kgm2.

For wrist down (0o deviation from the vertical line). Max load = 215 kg, Zmax = 0,310m and Lmax = 0,133m

Product Specification IRB 6600 M2000

15

Description Load diagram for IRB 6600-225/2.55 0,90

100 kg

0,80

0,70

120 kg

0,60

Z-distance (m)

150 kg

0,50

175 kg 200 kg

0,40

215 kg 220 kg

0,30

225 kg 230 kg

0,20

200 mm

0,10

0,00 0,00

0,10 0,10

0,20 0,20

0,30

0,40

0,50

0,60

L-distance (m)

Figure 9 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity).

16

Product Specification IRB 6600 M2000

Description Load diagram for IRB 6600-225/2.55 “Vertical Wrist” (±10o)

L

“Vertical wrist”

Load diagram "Vertical Wrist" (±10°)

Pay load 10o 10o

IRB 6600 - 225/2.55 Armload: 50kg

200 mm

Z L-distance (m) 0,00

0,20

0,40

0,60

0,80

1,00

1,20

1,40

0,00

0,20

260 kg 235 kg 0,40

200 kg Z-distance (m)

0,60

150 kg 0,80

100 kg 1,00

1,20

1,40

1,60

Figure 10 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist” (±10o).

For wrist down (0o deviation from the vertical line). Max load = 270 kg, Zmax = 0,359m and Lmax = 0,124m

Product Specification IRB 6600 M2000

17

Description Load diagram for IRB 6600-175/2.8 1,10

1,00

80 kg 0,90

100 kg

0,80

Z-distance (m)

0,70

120 kg

0,60

150 kg 0,50

170 kg 0,40

175 kg 0,30

180 kg 185 kg

0,20

200 mm

0,10

0,00 0,00

0,10 0,10

0,20 0,20

0,30

0,40

0,50

0,60

0,70

L-distance (m )

Figure 11 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity)..

18

Product Specification IRB 6600 M2000

Description Load diagram for IRB 6600-175/2.8 “Vertical Wrist” (±10o)

L

“Vertical wrist”

Pay load

200 mm

10o 10o L-distance (m ) 0,00

0,20

0,40

0,60

0,80

1,00

1,20

1,40

Z

0,00

0,20

210 kg 190 kg 0,40 Z-distance (m)

170 kg 125 kg 0,60

100 kg 0,80

1,00

1,20

Figure 12 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist” (±10o).

For wrist down (0o deviation from the vertical line) Max load = 215 kg, Zmax = 0,382m and Lmax = 0,116m

Product Specification IRB 6600 M2000

19

Description Load diagram for IRB 6650-125/3.2

1,10

1,00

80 kg

0,90

90 kg 0,80

100 kg

0,70

Z-distance (m)

110 kg 0,60

115 kg 0,50

120 kg 0,40

125 kg 0,30

130 kg 0,20

200 mm

0,10

0,00 0,00

0,10

0,20 0,20

0,30

0,40

0,50

0,60

0,70

L-distance (m)

Figure 13 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity)..

20

Product Specification IRB 6600 M2000

Description Load diagram for IRB 6650-125/3.2 “Vertical Wrist” (±10o)

L

“Vertical wrist”

Load diagram "Vertical Wrist" (±10°)

Pay load 10o 10o

IRB 6650 - 125/3.20 Armload: 50kg 200 mm

L-distance (m)

Z 0,0

0,2 0,20

0,4 0,40

0,6 0,60

0,8 0,80

1,0 1,00

1,2 1,20

1,4 1,40

1,6 1,60

0,0

150 kg 0,20 0,2 135 kg 0,40 0,4 120 kg Z-distance (m)

110 kg 0,6 0,60

100 kg 0,8 0,80

1,0 1,00

1,2 1,20

1,4 1,40

1,60 1,6

Figure 14 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist” (±10o).

For wrist down (0o deviation from the vertical line) Max load = 150 kg, Zmax = 0,462m and Lmax = 0,156m

Product Specification IRB 6600 M2000

21

Description Load diagram for IRB 6650-200/2.75

0,90

0,80

100 kg

0,70

120 kg 135 kg

0,60

Z-distance (m)

150 kg 0,50

175 kg

195 kg

0,40

200 kg 0,30

205 kg 210 kg

0,20

200 mm

0,10

0,00 0,00

0,10 0,10

0,20

0,30

0,40

0,50

0,60

L-distance (m)

Figure 15 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity).

22

Product Specification IRB 6600 M2000

Description Load diagram for IRB 6650-200/2.75 “Vertical Wrist” (±10o)

L

“Vertical wrist”

Pay load 10o 10o

Load diagram "Vertical Wrist" (±10°) IRB 6650 - 200/2.75 Armload: 50kg

Z 200 mm

L-distance (m) 0,0

0,2 0,20

0,4 0,40

0,6 0,60

0,8 0,80

1,0 1,00

1,2 1,20

1,4 1,40

0,0

235 kg 0,20 0,2 210 kg Z-distance (m)

0,4 0,40

175 kg 0,60 0,6 125 kg 0,80 0,8 100 kg 1,0 1,00

1,2 1,20

1,4 1,40

Figure 16 Maximum permitted load mounted on the robot tool flange at different positions (centre of gravity) at “Vertical Wrist” (±10o).

For wrist down (0o deviation from the vertical line) Max load = 245 kg, Zmax = 0,345m and Lmax = 0,098m

Product Specification IRB 6600 M2000

23

Description Maximum load and moment of inertia for full and limited axis 5 (centre line down) movement. Note. Load in kg, Z and L in m and J in kgm2 Full movement of axis 5 (±120o): Axis 5 Maximum moment of inertia: Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and -200/2.75

≤ 195 kgm2 for: -175/2.55 Axis 6 Maximum moment of inertia: Ja6 = Load • L2 + J0Z

≤ 185 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and -200/2.75

≤ 145 kgm2 for: -175/2.55

Z

X

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

Figure 17 Moment of inertia when full movement of axis 5.

Limited axis 5, centre line down: Axis 5 Maximum moment of inertia: Ja5 = Load • ((Z + 0,200)2 + L2) + J0L ≤ 275kgm2 for: -225/2.55, -175/2.8, -125/3.2 and ≤ 215 Axis 6 Maximum moment of inertia: Ja6 = Load • L2 + J0Z

kgm2

-200/2.75 for: -175/2.55

≤ 250 kgm2 for: -225/2.55, -175/2.8, -125/3.2 and -200/2.75

≤ 195 kgm2 for: -175/2.55

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

X

Z Figure 18 Moment of inertia when axis 5 centre line down.

24

Product Specification IRB 6600 M2000

Description Mounting equipment Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame. Definitions of distances and masses are shown in Figure 19 and Figure 20. The robot is supplied with holes for mounting extra equipment (see Figure 21). Maximum permitted arm load depends on centre of gravity of arm load and robot payload. Upper arm Permitted extra load on upper arm housing plus the maximum handling weight (See Figure 19): M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension. /

a

M1

Mass centre M1

Figure 19 Permitted extra load on upper arm.

Frame (Hip Load) Permitted extra load on frame is JH = 200 kgm2 Recommended position (see Figure 20). JH = JH0 + M4 • R2 where

JH0 R M4

is the moment of inertia of the equipment is the radius (m) from the centre of axis 1 is the total mass (kg) of the equipment including bracket and harness (≤500 kg)

527

457

R

790 1195

View from above

View from the rear

Figure 20 Extra load on the frame of IRB 6600 (dimensions in mm).

Product Specification IRB 6600 M2000

25

Description Mounting of hip load The extra load can be mounted on the frame. Holes for mounting see Figure 21 and Figure 22. When mounting on the frame all the four holes (2x2, ∅16) on one side must be used.

520 IRB 6600 725 IRB 6650

400 IRB 6600 500 IRB 6650

Holes for mounting extra equipment

Figure 21 Holes for mounting extra equipment on the upper and the lower arm, and the frame (dimensions in mm).

26

Product Specification IRB 6600 M2000

Description

Figure 22 Holes for mounting of extra load on the upper arm (dimensions in mm).

Product Specification IRB 6600 M2000

27

Description

IRB 6600-175/2.55 1,6

0,04 A 12 H7 Depth 15

A

15 A

2

) o (12x 30

R

B

B

A

A-A 0,02 CD

99 100 H7 Depth 8 min 160

0,02 A

B-B M12 ( 11x ) 0,2 A B

Figure 23 Robot tool flange (dimensions in mm).

28

Product Specification IRB 6600 M2000

Description

IRB 6600-225/2.55 IRB 6600-175/2.8 IRB 6650-125/3.2 IRB 6650-125/3.2

1 1,6

2 0,04 A

A

12 H7 Depth 15

15 A

1,6 B

B

B

A

0,02 C D

A-A

0,02 A

100 H7 Depth 8 min

M12 ( 11x ) 0,2 A B

160

B-B

Figure 24 Robot tool flange (dimensions in mm).

Product Specification IRB 6600 M2000

29

Description

1.5 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - Maintenance-free AC motors are used. - Oil is used for the gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change. The following maintenance is required: - Changing filter for the transformer/drive unit cooling every year. - Changing batteries every third year. The maintenance intervals depend on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.

30

Product Specification IRB 6600 M2000

Description

1.6 Robot Motion Type of motion

Range of movement

Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6

+180o +85o +70o +300o +120o +300o

Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion

to to to to to to

-180o -65o -180o -300o -120o -300o

IRB 6600-175/2.55 IRB 6600-225/2.55

Figure 25 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

Product Specification IRB 6600 M2000

31

Description

IRB 6600-175/2.8

Figure 26 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

32

Product Specification IRB 6600 M2000

Description

IRB 6650-125/3.2

Figure 27 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

IRB 6650-200/2.75

Figure 28 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

Product Specification IRB 6600 M2000

33

Description Performance according to ISO 9283 At rated maximum load, maximum offset and 1.6 m/s velocity (for IRB 6600-225/2.55, 1.0 m/s velocity) on the inclined ISO test plane, 1 m cube with all six axes in motion. Data for IRB 6650 not yet available. IRB 6600 -175/2.55 Pose accuracy, AP 0.09 mm Pose repeatability, RP 0.18 mm Path repeatability, RT 1.05 mm Pose stabilization time, Pst 0.03 s

-225/2.55 0.11 mm 0.18 mm 0.36 mm 0.55 s*

-175/2.8 0.13 mm 0.20 mm 0.32 mm 0.21 s

* Too close limit Velocity Maximum axis speeds.

Axis no. 1 2 3 4 5 6

IRB 6600-175/2.55 IRB 6600-225/2.55 IRB 6600-175/2.8 IRB 6650-200/2.75

IRB 6650-125/3.2

100°/s 90°/s 90°/s 150°/s 120°/s 190°/s

110°/s 90°/s 90°/s 150°/s 120°/s 235°/s

1.7 Cooling fan for axis 1-3 motor (option 113-115) A motor of the robot needs a fan to avoid overheating if the avarage speed over time exceeds the value given in Table 1. The maximum allowed avarage speed is depending on the load. The average speed can be calculated with the following formula: Average speed =

Total axis movement, number of degrees, in one cycle 360 x cycle time (minutes) incl. waiting time

The maximum allowed average speed for axis 1-3 at the maximum ambient temperature of 50oC according to Table 1. IP 54 for cooling fan. Table 1

Variant

34

Maximum average speed axis 1 (rpm)

Maximum average speed axis 2 (rpm)

Maximum average speed axis 3 (rpm)

IRB 6600-175/2.55

8.1 - 10.5

2.4 - 2.6

4.7 - 6.1

IRB 6600-225/2.55

7.8 - 10.1

2.1 - 2.3

3.1 - 4.0

IRB 6600-175/2.8

7.8 - 10.1

2.1 - 2.3

3.1 - 4.0

IRB 6650-125/3.2

4.9 - 6.3

2.1 - 2.3

3.1 - 4.0

IRB 6650-200/2.75

7.8 - 10.1

2.1 - 2.3

3.1 - 4.0

Product Specification IRB 6600 M2000

Description

1.8 SpotPack and DressPack The different robot types can be equipped with the option SpotPack for IRB6600/6650. The SpotPack IRB6600/6650 is designed for spot welding and handling applications. The function package supplies the transformer gun or the robot gripper with necessary media, such as compressed air, cooling water and electrical power. SpotPack IRB6600/6650 can be delivered in three standard versions developed for three different applications: • SpotPack IRB6600/6650 Type S is designed for transformer guns carried by the robot manipulator. • SpotPack IRB6600/6650 Type HS is designed for transformer guns mounted on a pedestal. • SpotPack IRB6600/6650 Type H is designed for material handling, using the same DressPack as type HS.

SpotPack IRB 6600 / 6650

Robot carried Gun Type S

Product Specification IRB 6600 M2000

Pedestal Gun Type HS

Material Handling Type H

35

Description The SpotPack for IRB6600/6650 is modular based and contains the main modules shown in the schematic picture below. Option description specifies different module combinations.

Robot gun/gripper

Upper arm harness

Lower arm harness Power unit Water and air unit Control Cabinet

Pedestal gun

Floor harness

Figure 29 SpotPack IRB6600/6650 main modules.

The modules Upper arm harness, Lower arm harness and Floor harness are in different combinations described as DressPack. The DressPack for upper and lower arm harness contains signals, process media (water and air) and power feeding (for Spotwelding power) for customer use. The floor harness for DressPack contains customer signals. To form a complete SpotPack also a Water and Air unit with hoses, Power unit with power cable and signal cables between these units are required.

36

Product Specification IRB 6600 M2000

Description Description of DressPack The DressPack contains the maximum wire and media capacity as described below. The number of signals that are available in each case depends on the choice of different option combinations (see option description). The interface connectors for the signals are also specified under each option description. Material handling application The cables and hose which are used to form the DressPack for the Material Handling application has the following specification and capacity: Table 2

Type

Pcs

Area

Allowed capacity

Customer Power (CP) Utility Power Protective Earth

2+2 1

0,5 mm2 1,0 mm2

500 VAC, 5 A rms 500 VAC

19 4

0,23 mm2 0,23 mm2

50 VAC/DC, 1 A rms 50 VAC/DC, 1 A rms

Customer Bus (CBus) Bus signals Bus signals Bus signals Bus utility signals

2 2 4 4

0,18 mm2 0,18 mm2 0,18 mm2 0,23 mm2

Profibus 12 Mbit/s spec* Can/DeviceNet spec* Interbus spec* 50 VAC/DC, 1 A rms

Media Air (PROC 1)

1

12,5 mm inner diameter

Max. pressure 16 bar / 230 PSI

Customer Signals (CS) Signals twisted pair Signals twisted pair and separate shielded

*

Quad twisted under separate screen. Can also be used for very sinsitive signals

Product Specification IRB 6600 M2000

37

Description Spot Welding application The cables and hoses used for the DressPack for the Spot Welding application has the following specification and capacity: Table 3

Type

Pcs

Area

Allowed capacity

Customer Power (CP) Servo motor power Utility Power Protective Earth

3 2+2 1

1,5 mm2 0,5 mm2 1,5 mm2

600 VAC, 12 A rms 500 VAC, 5 A rms 500 VAC

19* 4

0,23 mm2 0,23 mm2

50 VAC/DC, 1 A rms 50 VAC/DC, 1 A rms

2 2 4 4

0,18 mm2 0,18 mm2 0,18 mm2 0,23 mm2

Profibus 12 Mbit/s spec** Can/DeviceNet spec** Interbus spec** 50 VAC/DC, 1 A rms

2 1

35mm2 35mm2

600 VAC***

2 1

25mm2 25mm2

600 VAC****

12,5 mm inner diameter

Max. air pressure 16 bar / 230 PSI. Max water pressure 10 bar / 145 PSI

Customer Signals (CS) Signals twisted pair Signals twisted pair and separate shielded Customer Bus (CBus) Bus signals Bus signals Bus signals Bus utility signals Welding power (WELD) Lower arm harness Lower arm harness protective earth Upper arm harness Upper arm harness protective earth Media Water/Air (PROC 3-4)

3-4

*

If servo gun application (S or HS) is used some signals will be occupied for motor control. ** Quad twisted under separate screen. Can also be used for very sensitive signals. *** 150 A rms at + 20°C (68F) ambient temp, 120 A rms at + 50°C (122F) ambient temp **** 135 A rms at + 20°C (68F) ambient temp, 100 A rms at + 50°C (122F) ambient temp

38

Product Specification IRB 6600 M2000

Description Description of Water and Air unit The Water and Air unit contains components for water and air distribution and control within the SpotPack. The water and air unit is via the process software controlled from the robot controller. Wiring is made via the power unit. The capacity and functionality depends on the choice of different option combinations, see option description. The unit is mounted at the manipulator base. Control cables to the unit has quick connectors in both ends and has the same cable length as the one specified for the robot control cable. The unit is only used for the spot welding applications. Table 4

Type

Pcs

Connections for media Incoming water Outgoing water Incoming air Extra air outlet *

1 1 1 1

Specification Parker PushLock fitting, M22 (conical angle 24°)* Parker PushLock fitting, M22 (conical angle 24°)* Parker PushLock fitting, M22 (conical angle 24°)* 1/2" connection. **

Max air pressure 16 bar / 230 PSI, max water pressure 10 bar / 145 PSI. (Parker Pushlock reference 3C382-15-8BK, brass version)

** Plugged at delivery (to be used for tip-dresser or other equipment). (Fitting 1/2" BSP 1,5). Signals for water and air unit: Electrical connections to robot I/O board are made via the splitbox on the water and air unit. Total 6 x M12 connections (4 pins) are available. The number in use depends on option choices but minimum 2 are in use within the SpotPack. Free connections can be used for customer purpose like tip-dresser control (Max 0,5 amp, 24 DC Volt).

Product Specification IRB 6600 M2000

39

Description Description of Power Unit The Power unit contains components for power distribution and control within the SpotPack. The power unit with the welding controller built in, is controlled from the robot controller via the process software.. Wiring is made between robot controller (I/O-board and internal cabling in the DressPack) and the power unit. The capacity and functionality depends by the choice of different option combinations. All cables are connected on the left hand side of the power unit. The unit is placed on top of the robot controller. The unit is only used for the spot welding applications. Two basic versions are available, Type S for Spotwelding with robot handled gun and Type HS for Spotwelding with pedestal gun. Table 5

Type

Pcs

Area

Allowed capacity

__ VAC, __A 50/60 Hz

Connections for power unit Incoming power from line

1

Outgoing power to robot

1

Floor cable Floor cable protective earth

2 1

Cable gland min __ mm/max __ mm cable* Cable gland min __ mm/max __ mm cable* 35mm2 35mm2

Signals Water and Air unit Pedestal gun

1 1

Modular Harting connector*** 50 VAC/DC, 1 A rms Modular Harting connector*** 50 VAC/DC, 1 A rms

*

__ VAC, __A 50/60 Hz 600 VAC** 600 VAC

Incoming power connection made by customer. For incoming power recommendations see Installation and Maintenance manual.

** 150 A rms at + 20°C (68F) ambient temp and 120 A rms at + 50°C (122F) ambient temp *** The connector type at the power unit is Han compact, HD insert.. Protection class for the power unit is IP54.

40

Product Specification IRB 6600 M2000

Description

1.9 Description of Variants and Options for SpotPack The following specification describes all main parts with main data for the SpotPack and Dresspack IRB 6600/6650. Required options for SpotPack IRB 6600/6650 different types To enable the spot welding function package SpotPack IRB 6600/6650 to perform as intended, general standard robot options for the three different types are required. These standard options are described under other chapters but are also mentioned in this chapter. SpotPack Type S standard requires the following general robot options: Option 122 Option 201 Option 251 Option 206 Option 553

No upper cover on robot control cabinet 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs. Internal connection of I/O Internal connection of safety signals SpotWare (software option for pneumatic guns)

SpotPack Type HS standard requires following general robot options: Option 122 Option 201 Option 251 Option 206 Option 553

No upper cover on robot control cabinet 1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs. Internal connection of I/O Internal connection of safety signals SpotWare (software option for pneumatic guns)

SpotPack Type H standard requires no general robot options. 1.9.1 Required options for SpotPack IRB 6600/6650 different types with servo gun To enable the spot welding function package SpotPack IRB 6600/6650 to run with a servo controlled gun, some additional (additional to those described in chapter 2.1) servo drive options for the two different types are required. These standard options are described under other chapters but are also mentioned below in this chapter. SpotPack Type S with servo requires the following additional options: Option 381 Option 702 Option 681-684 Option 625

Drive unit type DDU-U Robot Gun. Connection of servo gun (7-30 m) SpotWare Servo (software option for servo guns) (replaces option 553). Also option 631, Servo tool change, should be added if servo gun tool change is required. (The option 561, Servo Tool Control, could be an alternative to 625 if the application software is designed by the customer. Option 561 is not used in the SpotPack as this is intended to be a ready to use package).

Product Specification IRB 6600 M2000

41

Description SpotPack Type HS with servo requires the following additional options: Option 381 Option 702 Option 686-689 Option 625

42

Drive unit type DDU-U Stationary Gun. Connection of servo gun (7 - 30 m) SpotWare Servo (software option for servo guns) replaces option 553). (The option 561, Servo Tool Control, could be an alternative to 625 if the application software is designed by the customer. Option 561 is not used in the SpotPack as this is intended to be a ready to use package).

Product Specification IRB 6600 M2000

Description 1.9.2 DressPack options Dress Pack options includes options for Upper arm harness, Lower arm harness and Floor harness. These are described separated below but are designed and meant to be seen as a complete package for either Material handling or Spot welding application. The Upper Arm Harness consists of a process cable package and supports, clamps, brackets and a retractor arm. The process cable package contains special designed cables and hoses that have been long term tested. The cables and hoses are partly placed in a protective hose to extend the lifetime. The Upper Arm Harness is designed to follow the robot arm movements and minimise damages to the harness or the robot manipulator. The interface to the lower arm harness is located well protected below the motor for axis 3. The complete harness is tested and proven to be well suited for both spot welding applications and other applications with the same type of movements and very high requirements. The cable and hose package has a 1000-mm free length at axis 6 for connection to a spot welding gun or a gripper. A tension arm unit keeps hose package in the right position for the robot arm movement approved for the SpotPack. An arm protection will prevent wear on the protective hose and on the robot itself. Please note that when the robot is operating, some multiply axis movement might end up with an overstraining of the hose package. These movements must be avoided. For more information see the Installation and Maintenance Manual. Process Cable package Harness support axis 6 Tension arm unit

Arm protection

Figure 30 Mechanical equipment upper arm harness.

Note. The upper arm harness specification is based on the sselection of lower arm harness. The Lower Arm Harness consists of a process cable package and supports, clamps and brackets. The process cable package, containing special designed cables and hoses, has been long term tested. The process cable package is routed along the lower arm to minimise space required and to give no limitation in the robot working envelope. The cables and hoses are partly placed in a protective hose to extend the lifetime. Product Specification IRB 6600 M2000

43

Description The lower arm harness is connected to the upper arm harness at the connection point under the axis 3 motor. The interface plate at the manipulator base is the place where the floor harness and the process media are connected. The Floor Harness consists of signal cables for customer signals. The floor harness is connected to the lower arm harness at the interface plate at the manipulator base and to the left side of the robot control cabinet. The signal connection inside the robot control cabinet depends on chosen options. As example will servo gun option, bus option and parallel option mean different connections. Process cable package For material handling and spot welding the DressPack can be chosen in different configurations. The part of the DressPack changing between different options are basically the process cable package and the brackets etc are the same. Initially general configurations for the process cable package is specified. With this as a base, the details of the application signals and media are added. Option 056 Connection to manipulator No floor cables for the DressPack are chosen. The connector at the base for interfacing is specified in installation and maintenance manual. Terminal connections could be found in the circuit diagrams. Option 057 Connection to cabinet Floor cables for the DressPack are chosen. Number of cables and cable type depends on chosen options. The length of the process cable package at the floor is specified under the options below: - Option 675-678 for parallel communication - Option 660-663 for bus communication with Can/DeviceNet - Option 665-668 for bus communication with Profibus - Option 670-673 for bus communication with Interbus The connection inside the cabinet depends on communication type. - If parallel communication is chosen, signals are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6) - If bus communication is chosen, signals are routed both to valid bus card. The remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).

44

Product Specification IRB 6600 M2000

Description Communication Option 2063 Parallel communication The process cable package has been chosen for parallel communication. The number as well as the type of signals are defined under Material handling application (Option 2204,2205) and Spot welding application (Option 2200). Option 2064 Bus communication The process cable package has been chosen for bus communication. This alternative includes both the signals for the bus communication as well as some parallel signals. The number as well as the type of signals are defined under Material handling application (Option 2204,2205) and also Spot welding application (Option 2200). This option can not be combined with servo gun application. The type of bus are defined by choice of floor cabling (see also option 057) Option 2204 Material Handling axis 1 to axis 3 The Lower arm harness for the Material Handling has been chosen. This includes the process cable package as well as brackets, connectors etc to form a complete dressing package from manipulator base until connectors on axis 3. Depending on the choice above the process cable package will have different content. See tables below. For all process cable packages some of the content is common. These common parts for Material Handling application are shown in Table 6 below. Unique parts for different option combinations are shown in Table 7, Table 8, Table 9 and Table 10. These tables are valid for option 2204 and 2205. Table for Common content Material Handling (with option 2063/2064) Table 6

Type

Pcs at Connection point

Note

Allowed capacity

1

12,5 m inner diameter

Max pressure 16 bar / 230 PSI

Media Air (PROC 1)

Product Specification IRB 6600 M2000

45

Description Table for Material Handling with option 2063 with or without Servo gun option 701 Table 7

Type Customer Power (CP) Utility Power Protective earth Customer Signals (CS) Signals twisted pair Signals twisted pair and separate shielded

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

19 4

19 4

50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen ** At manipulator base or axis 3 interface (or axis 6 under option 2205) Table for Material Handling with option 2064 and Can/DeviceNet Table 8

Type Customer Power (CP) Utility Power Protective earth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 4

2 2 4 4

Can/DeviceNet spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen ** At manipulator base or axis 3 interface (or axis 6 under option 2205)

46

Product Specification IRB 6600 M2000

Description

Table for Material Handling with option 2064 and Interbus Table 9

Type Customer Power (CP) Utility Power Protective earth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 3

4 1 4 3

Interbus spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen ** At manipulator base or axis 3 interface (or axis 6 under option 2205) Table for Material Handling with option 2064 and Profibus Table 10

Type Customer Power (CP) Utility Power Protective earth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 4

2 2 4 4

Profibus 12Mbit/s spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen ** At manipulator base or axis 3 interface (or axis 6 under option 2205) Option 2205 Material Handling axis 3 to axis 6 The Upper arm harness for the Material Handling has been chosen. This includes the process cable package as well as brackets, connectors etc to form a complete dressing package from interface at axis 3 to the connectors at axis 6. Depending on the earlier choice (see option 2204) the process cable package will have different content. For content see Table 6, Table 7, Table 8, Table 9 and Table 10. The connector type at the manipulator base, at axis 3 and axis 6 is specified in the Installation and maintenance manual.

Product Specification IRB 6600 M2000

47

Description Option 2200 Spot Welding to axis 3, and option 2201 Spot Welding to axis 6 The Lower arm harness and the Upper arm harness for Spot Welding has been chosen. This includes the process cable package as well as brackets, connectors etc to form a complete dressing package from manipulator base to the connectors on axis 6. Depending on the earlier choice above the process cable package will have different content. See tables below. For further details see Installation and maintenance manual and circuit diagrams For all process cable packages some of the content are common. These common parts for Spot Welding application are shown in table 11 below. Unique parts for different option combinations are showed in Table 12, Table 13, Table 14, Table 15 and Table 16. Table for common content Spot Welding (with option 2063/2064) Table 11

Type Welding Power (WP) Lower arm harness Lower arm harness protective earth Upper arm harness Upper arm harness protective earth Media Water/Air (PROC 1-3)

Pcs at Connection point*

Note

Allowed capacity

2 1

35 mm2 35 mm2

600 VAC**

2 1

25 mm2 25 mm2

600 VAC***

3

12,5 mm inner diameter

Max. air pressure 16 bar/ 230 PSI. Max. water pressure 10 bar/145 PSI

* **

At manipulator base or axis 6. 150 A rms at + 20°C (68F) ambient temp, 120 A rms at + 50°C (122F) ambient temp *** 135 A rms at + 20°C (68F) ambient temp, 100 A rms at + 50°C (122F) ambient temp

48

Product Specification IRB 6600 M2000

Description Table for Spot Welding with option 2063 Table 12

Type Customer Power (CP) Utility Power Protective earth Customer Signals (CS) Signals twisted pair Signals twisted pair and separate shielded

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

19* 4*

19* 4*

50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen. ** At manipulator base or axis 6. Table for Spot Welding with option 2063 and servo gun option 702 Table 13

Type Customer Power (CP) Servo motor Power Utility Power Protective earth Customer Signals (CS) Signals twisted pair Signals twisted pair and separate shielded

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

3 2+2 1

600 VAC, 12 A rms 500 VAC, 5 A rms 500 VAC

4* 4*

4* 4*

50 VAC, 1 A rms 50 VAC, 1 A rms

*

Terminals inside the cabinet if option 057 is chosen. Signals needed for servo gun motor control are not specified above. ** At manipulator base or axis 6.

Product Specification IRB 6600 M2000

49

Description Table for Spot Welding with option 2064 and CAN/DeviceNet Table 14

Type Customer Power (CP) Utility Power Protective earth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 4

2 2 4 4

CAN/DeviceNet spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen. ** At manipulator base or axis 6. Table for Spot Welding with option 2064 and Interbus Table 15

Type Customer Power (CP) Utility Power Protective arth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 3

4 1 4 3

Interbus spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen. ** At manipulator base or axis 6.

50

Product Specification IRB 6600 M2000

Description Table for Spot Welding with option 2064 and Profibus Table 16

Type

Customer Power (CP) Utility Power Protective earth Customer Bus (CBus) Bus signals Bus signals Signals twisted pair Utility signals

Pcs at Terminal*

Pcs at Connection point**

Allowed capacity

2+2 1

2+2 1

500 VAC, 5 A rms 500 VAC

4 4

2 2 4 4

Profibus 12Mbit/s spec 50 VAC, 1 A rms 50 VAC, 1 A rms 50 VAC, 1 A rms

* Terminals inside the cabinet if option 057 is chosen ** At manipulator base or axis 3 interface (or axis 6 under option 2205) Option 2065 Extended media The process cable package from foot to axis 6 can be extended with an extra media hose. This could only be chosen in combination Spot welding application (with option 2200, all variants shown in Table 12, Table 13, Table 14, Table 15 and Table 16). This option has the following specification: - Hose 1/2" (Proc 4) with connection (Parker Pushlock reference 3C382-158BK, brass version) both at foot and at axis 3. At axis 6 with free end. Option 2070 Connection kit, Axis 6 robot side SW The process cable package from manipulator base to axis 6 (option 2200) ends with free end for media and for weld power cable. If this option is chosen a kit for connections will be supplied. This has to be assembled by the customer when hoses and power cable has been cut to required length. The kit contains: - 4 Hose fittings, Parker Push lock type with conical angel 24 Degrees (Parker Pushlock reference 3C382-15-8BK, brass version). - 1 Multi contact connector (Female).

Product Specification IRB 6600 M2000

51

Description 1.9.3 Power Unit The standard Power unit for SpotPack contains the electric components and circuits needed for spot welding. The power unit cabinet is designed to be placed on top of the robot control cabinet, see picture below, and secured with four attachment plates. The power unit should be seen as a main part of the complete SpotPack (type S and HS) and normally not handled as a separate unit. The electrical circuits of the power unit consist of weld power circuit and control circuits to control the welding. Weld power circuit The welding power for the welding gun is fed through a circuit breaker and welding thyristor (for AC welding) or inverter (for MFDC welding) and further out to the welding power cable. The welding power cable is connected directly to the thyristor/ inverter. Control Circuits Power 240 V AC and 24 V DC for the control circuits is fed from the robot cabinet. Also the safety circuits in the robot cabinet is used to interlock the welding timer. A welding timer (Bosch), integrated with the air cooled thyristor or inverter, controls the welding current. The welding timer includes control program which gives possibility to program different weld sequence. The programming is normally done on a PC that is connected directly to the welding timer. The interface between the robot system and the welding timer is handled via a digital signal interface. Example of signals are weld start, weld ready, weld program choice and error. Also cross connections, of interface signals and interlocking between the robot system (I/O-boards), the water and air unit, signals to DressPack and pedestal / stationary gun (type HS), are done within the power unit. For further information see Installation and Maintenance manual and separate manuals for the Bosch equipment. Programming device for the welding timer is not included. Option 2087 Power unit, AC welding type S The basic power unit for type S is equipped for a robot handled AC Spotwelding gun and with the following components: - Cable gland for incoming power (X100) - Circuit Breaker type ABB SACE, T1 160 A - Welding Timer and Thyristor type Bosch PST 6100.100L 76kVA - Fuse terminal for 24 V distribution - Connector to Water and air unit, Modular Harting. (XS103) - Cable gland for outgoing power (X101). (For power cable see option 2095/ 2096) For further information see Installation and Maintenance manual, circuit diagrams and separate manuals for the Bosch equipment. 52

Product Specification IRB 6600 M2000

Description Option 2088 Power unit, AC welding type HS The basic power unit for type HS is equipped for a stationary / pedestal mounted AC Spotwelding gun and with the following components: - Cable gland for incoming power (X100) - Circuit Breaker type ABB SACE, T1160 A - Welding Timer and Thyristor type Bosch PST 6100.100L76kVA - Fuse terminal for 24 V distribution - Connector to Water and air unit, Modular Harting. (XS103) - Connector to pedestal gun, Modular Harting (XS 104). (For process cables to Stationary gun see option 2117, 2118 and 2119) - Cable gland for outgoing power (X101). For power cable (see option 2095/ 2096) For further information see Installation and Maintenance manual, circuit diagrams and separate manuals for the Bosch equipment. Option 2090 MFDC welding S and HS This option replaces the thyristor unit in option 2087 or 2088, with a MFDC inverter type Bosch PSI 6100.100L. This option requires forced air cooling (option 2091). Option 2091 Forced air cooling This option adds a cooling fan with housing placed on the rear of the power unit. This forces air on the cooling surface for the thyristor or MFDC converter. For the MFDC converter this is mandatory. For the AC thyristor the need of the forced air cooling depends on the load and the ambient temperature. For further information see separate manuals for the Bosch equipment. Option 2092 Earth fault protection This option adds an earth fault protection to the circuit breaker. This protection could be used for AC welding or MFDC welding. The sensitivity of the earth fault protection could be adjusted. If and earth fault occurs the circuit breaker is tripped. For further information see Installation and Maintenance manual, circuit diagrams and separate specifications of the earth fault protection. Option 2093 Contactor for weld power This option adds a contactor with necessary wiring and relays inside the power unit. This contactor could be used to disconnect power to the gun at for example tool change. Option 2095 Weld power cable, 7m This option includes floor cable of 7 m length for weld power. This is connected at terminals inside the control cabinet and with an MC connector at manipulator base. The cable has an allowed capacity of 150 A rms at + 20°C (68F) ambient temp and 120 A rms at + 50°C (122F) ambient temp.

Product Specification IRB 6600 M2000

53

Description Option 2096 Weld power cable, 15 m This option includes floor cable of 15 m length for weld power. See description for option 2095. Option 2117 Process cable to stationary gun, 7m This option includes floor cable of 7 m length for process signals to the pedestal/ stationary gun. This cable is connect to the Power unit (option 2088) with a modular harting. The cable ends also with a modular harting where the customer could connect control signals for the gun. For further information about connector and available signals see Installation and Maintenance manual and circuit diagrams. Option 2118 Process cable to stationary gun, 15m This option includes floor cable of 15 m length for weld power. See description for option 2117. Option 2119 Process cable to stationary gun, 30m This option includes floor cable of 30 m length for weld power. See description for option 2117. 1.9.4 Water and Air Unit The water and air unit is the connection point for cooling water and compressed air to the spot welding gun. All standard features and options are the same for types S and HS. Water and air unit is not included for type H. The standard water and air unit is mounted at the base of the robot. The standard water and air unit consists of four main assemblies: - Water in circuit - Water return circuit - Air supply circuit - Split box Cables and hoses required for Water and Air unit are defined and described under each option for water and air unit. Water in circuit The function of the water in circuit is to open / close the cooling water supply to the Spot welding gun. An electrically controlled valve with indication led is used. The valve is controlled by a digital signal from the robot control system. The circuit start from left with an Parker Puchlock 33482-8-8BK fitting for ½” hose (hose assembled by customer), manual shut off valve for the cooling water flow, electrical shut off valve and ends with a Parker Pushlock adapter. (Suitable for a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting). From this point the water is led to the gun/robot. 54

Product Specification IRB 6600 M2000

Description Water return circuit The water return circuit monitors the flow of the returning cooling water from the Spot welding gun. The flow switch detects if the water flow is too low in the cooling water circuit. The flow switch gives a digital signal to the robot control system, which automatically shuts the electrical shut off valve in the water in circuit off if the flow is too low. The system and the supply of cooling water are then automatically stopped to minimise any risk of damage to the system. The water return circuit is delivered with a pre-set flow limit, set to approx. 3,5 litres per minute. The water return circuit started from right with a Parker Pushlock adapter (Suitable for a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting), flowswitch with a switching point between 2-12 litres per minute. It’s also equipped with a flow control valve; the flow control can adjust the water flow to a wanted flow level. The flow-value can be monitored through a small window on the flow control valve. This will serve as a rough function check in the approximate flow range of 2-8 litres per minute. The circuit end’s with a check-valve that will stop any reversing water flow, manual shut off valve and an Parker Puchlock 33482-8-8BK fitting for ½” hose (hose assembled by customer). From this point the water is led to the factory water system. Air supply circuit The air supply circuit provides the robot and option: proportional valve with air supply. The air supply circuit started with a Parker Puchlock 39C82-15-8BK fitting (hose assembled by customer). Manually operated shut off valve to vent the system through a silencer, air filter 25 microns and a water separator equipped with a metal bowl protection, distribution block containing plugged air outlet ports. The air supply circuit ends with a Parker Pushlock adapter. (Suitable for a Parker Puchlock DIN 20 078 A, we recommend a Parker Pushlock 39C82-15-8BK fitting). Maximum flow capacity is 3000 litres per minute at 6.3 bar and P = 1.0 bar. Maximum allowed pressure is 16 bar. Split box With the split box, the 24VDC supply and signals are connected and distributed to the different units on the water and air unit, see picture below. The design makes disconnection of separate items for service and repair on the water and air unit very easy. The split box has a protection class IP68. Brand: Woodhead, Brad Harrison. The split box has six connections prepared for the following units. - Electric water shut off valve - Flow switch 1 - Flow switch 2 (Option 2177 Second Water Return) - Pressure switch (Option 2179 Pressure switch and Regulator for air) - Proportional valve (Option 2181 Electrical proportional valve for air) - Spare Product Specification IRB 6600 M2000

55

Description The cable and cable length between the Split box and the Power unit has to be specified (see option 2183, 2184 and 2185).

El. shut off

XS 101.1

Flow switch 1

XS 101.2

Flow switch 2

Air pressure switch

Proportonal Valve

Option

Option

Option

Spare

XS 101.3

XS 101.4

XS 101.5

XS 101.6

24V, parallel interface

Figure 31 Block diagram split box on Water and Air Unit

Option 2174 Water and Air unit, type S The basic water and air unit for type S is equipped for a robot handled gun and with the following components: - Water in circuit - Water return circuit - Air supply circuit - Split box - 1/2 " hose between air supply circuit and manipulator base (PROC 1) - 1/2 " hose between water in circuit and manipulator base (PROC 2) - 1/2 " hose between water return circuit and manipulator base (PROC 3) Option 2175 Water and Air unit, type HS The basic water and air unit for type HS is equipped for a pedestal/stationary gun and with the following components: - Water in circuit - Water return circuit - Air supply circuit - Split box - 1/2" hose between air supply circuit and manipulator base (PROC 1) 56

Product Specification IRB 6600 M2000

Description Hoses between water in circuit and water return circuit are not supplied. These have to be arranged by the customer. Option 2177 Second water return When the water pressure drop is to high because of too long hoses or because of any other reason, an additional water return circuit can be the best solution to solve this problem. For this extra water return circuit this option is required. It contains an extra flow switch to monitor the water coming from the second circuit. Two cooling water circuits also have the advantage of a more even cooling of the two sides of the Spotwelding gun compared to a single circuit system. For more information see under Flow switch in water return circuit. Please note that this option can not be combined with option 2181, Electrical proportional valve for air normally used together with a pneumatic robot mounted welding gun. The additional used water hose in this option is normally used for compressed air for pneumatic moved welding guns. Additional 1/2" water hose (PROC 4) to manipulator base is included. Option 2192 Digital flow meter, One water return If a digital flow meter is requested instead of a flow switch, this option should be chosen. This option is valid for one water return (if two water return see option 2193). This option means that the flow switch and the flow control valve with visible flow indication is replaced by the digital flow meter and a flow control valve without visible flow indication (not required as adjustments could be seen on the digital flow meter). The digital flow meter gives the following advantages compared to flow switch: - The biggest advantage is that the flow switch is mechanical function safe, that means if something damage the flow switch you will notice that immediacy - The actual flow could be seen direct on the display - The flow switch level and the tolerance could be set with high tolerance - The flow value could been monitored at distance with a remote display. Option 2193 Digital flow meter, Two water returns If the option second water return (option 2177) is chosen and the digital flow meter is requested this option should be chosen. For more information see option 2192. Option 2179 Pressure switch and regulator for air Option 2179, Filter regulator and pressure switch includes a manually operated pressure regulator to set the incoming pressure to the Spot welding gun. The pressure can be monitored on the included pressure gauge. This option also includes a Pressure Switch to monitor the air pressure and to give a signal to the control system if the pressure becomes to low. The 2179 include same components as Air Supply Circuit except that the filter changes to a filter regulator plus we add pressure gauge 0-16 bar and pressure Switch with belonging cable to splitbox.

Product Specification IRB 6600 M2000

57

Description Option 2181 Electrical proportional valve for air The option includes a proportional valve with integrated control circuit and connection cable to the splitbox. The proportional valve controls the pinching force of the pneumatic spot welding gun and is designed to obtain optimal performance during long operation time. The proportional valve is controlled by the weldtimer in the Power unit. The included distribution block can be used for two additional non-regulated compressed air circuits. An analogue signal 0-10V, controls the proportional valve and the air pressure is in the range of 0-12 bar. Option 2183 Cable to split box, 7m This option includes floor cable of 7 m length for signals to the split box sitting on the water and air unit. This cable is connect to the Power unit (option 2087/2088) with a modular harting (Han Compact with insert type HD). The cable ends also with a quick connector at the split box end. Option 2184 Cable to split box, 15m This option includes floor cable of 15 m length for the split box. See description for option 2183. Option 2185 Cable to split box, 30m This option includes floor cable of 30 m length for the split box. See description for option 2183.

58

Product Specification IRB 6600 M2000

Description

1.10 Examples of SpotPacks To support the understanding of how the different options could be combined to complete SpotPacks some examples are shown below. Note that these are examples of possible configurations and that each case has to be analysed based on the unique production conditions. Example 1: DressPack for Material Handling with Can/DeviceNet Option no

Name / Note

DressPack options 057

Connection to cabinet. Includes floor cables with signals to terminals inside controller

2064

Communication, Bus communication

2204

Material Handl. Axis 1 to 3 Lower arm harness to get the signals to axis 3

2205

Material Handl. Axis 3 to 6 Upper arm harness to get the signals to axis 6

660

Connection to cabinet, cable length, CAN/DeviceNet / 7m Specifies floor cable length and type of bus

Example 2: SpotPack for SpotWelding with pneumatic gun and parallel interface Option no

Name / Note

General options 122

No upper cover on robot control cabinet

201

1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs

251

Internal connection of I/O

206

Internal connection of safety signals

553

SpotWare (software option for pneumatic guns)

DressPack and SpotPack options 057

Connection to cabinet Includes floor cables with signals to terminals inside controller

2063

Communication, Parallel communication

2200

SpotWelding to axis 6 Lower arm and Upper arm harness to get the signals to axis 6

2065

Extended media SW Additional hose for regulated air via option 2181

675

Connection to cabinet, cable length, Parallel / 7m Specifies floor cable length with parallel interface

Product Specification IRB 6600 M2000

59

Description 2087

Power unit, AC welding type S AC welding with robot handled gun

2095

Weld power cable / 7m. Specifies power cable for welding

2174

Water and air unit / Type S

2181

Electrical proportional valve for air Programmable pressure for pneumatic gun

2183

Cable to split box / 7m Specifies floor cable length to split box

Example 3: SpotPack for SpotWelding with servo gun gun and parallel interface. Option no

Name / Note

General options 122

No upper cover on robot control cabinet

201

1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs

251

Internal connection of I/O

206

Internal connection of safety signals

Servo gun options 381

Drive unit type DDU-V

702

Robot Gun

681

Connection of servo gun 7m

625

SpotWare Servo (software option for servo guns)

DressPack and SpotPack options

60

057

Connection to cabinet Includes floor cables with signals to terminals inside controller

2063

Communication, Parallel communication

2200

SpotWelding to axis 6 Lower arm and Upper arm harness to get the signals to axis 6

675

Connection to cabinet, cable length, Parallel / 7m Specifies floor cable length with parallel interface

2087

Power unit, AC welding type S AC welding with robot handled gun

2090

MFDC welding S and HS Replaces AC welding with MFDC welding

2091

Forced air cooling. Air cooling of MFDC converter

2095

Weld power cable / 7m Specifies power cable for welding Product Specification IRB 6600 M2000

Description 2174

Water and air unit / Type S.

2183

Cable to split box / 7m Specifies floor cable length to split box

Example 4: SpotPack for SpotWelding with pedestal servo gun and Interbus interface to robot handled gripper. Option no

Name / Note

General options 122

No upper cover on robot control cabinet

201

1pc. Digital 24 VDC I/O 16 inputs/ 16 outputs.

251

Internal connection of I/O

206

Internal connection of safety signals

Servo gun options 381

Drive unit type DDU-V

701

Stationary Gun.

686

Stationary Servo gun 7m

625

SpotWare Servo (software option for servo guns)

DressPack and SpotPack options 057

Connection to cabinet Includes floor cables with signals to terminals inside controller

2064

Communication, Bus communication.

2200

SpotWelding to axis 6 Lower arm and Upper arm harness to get the signals to axis 6

670

Connection to cabinet, cable length, Interbus / 7m Specifies floor cable length with Interbus interface

248

Interbus Master/Slave, Copper wire. Interbus board in cabinet

2087

Power unit, AC welding type HS AC welding with pedestal gun

2095

Weld power cable / 7m Specifies power cable for welding

2117

Process cable to stationary gun, 7m Communication cable to stationary/pedestal gun

2175

Water and air unit / Type HS.

2183

Cable to split box / 7m Specifies floor cable length to split box

Product Specification IRB 6600 M2000

61

Description

1.11 Servo Gun (option) The robot can be supplied with hardware and software for Stationary Gun, Robot Gun, Stationary and Robot Gun, Twin Staionary Guns, Stationary Gun and Track Motion or Robot Gun and Track Motion. For configuration and specification of hardware and software respectively, see each section below. 1.11.1 Stationary Gun (SG)

M1

M2

CB1

D1

option 381

D2

DDU-V

(options 641-644)

option 701

M7C1B1.CFG

options 686-689

Figure 32 Configuration of Stationary Gun.

Options according to Table 17 are required to complete the delivery. For further details see corresponding Product Specification. Table 17

Option

62

Description

Product Spec.

381

DDU in a separate box and cable to cabinet

S4Cplus

686-689

Cables (7-30m) between DDU and SG

S4Cplus

701

Cables inside the manipulator and manipulator foot to SG

S4Cplus

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

Description 1.11.2 Robot Gun (RG) option 702

M1

M2

CB1

D1

D2

option 381

option 702 options 2063

DDU-V

options 697-699

(options 641-644)

Figure 33 Configuration of Robot Gun.

Options according to Table 18 below are required to complete the delivery. For further details see corresponding Product Specification. Table 18

Option

Description

Product Spec.

381

DDU in a separate box and cable to cabinet

S4Cplus

697-699

Extended cables (7-30m) between DDU and RG

S4Cplus

702

Cabling inside the controller and the manipulator

S4Cplus

2063

Parallel communication including Servo

IRB 6600

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

63

Description 1.11.3 Stationary and Robot Gun (SG + RG)

M1

M2

CB1

options 697-699 options 2063

D1

M1

M2

CB2

D2

D1

D2

option 382

option 703 DDU-VW SMB

M7C1B1.CFG

(options 641-644)

options 686-689

Figure 34 Configuration of Stationary and Robot Gun.

Options according to Table 19 below are required to complete the delivery. For further details see corresponding Product Specification. Table 19

Option

64

Description

Product Spec.

382

DDU in separate box and cable to the cabinet

S4Cplus

686-689

Cables (7-30m) between DDU and SG

S4Cplus

697-699

Extended cables (7-30m) between DDU and RG

S4Cplus

703

SMB box with cabling

S4Cplus

2063

Parallel communication inclusive of Servo

IRB 6600

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

Description 1.11.4 Twin Stationary Guns (SG + SG)

M1

M2

CB1

D1

M1

M2

CB2

D2

D1

option 382

D2

DDU-VW

(options 641-644) M7C1B1.CFG

SG 1

options 686-689

SMB SG 2

option 704

Figure 35 Configuration of Twin Stationary Guns.

Options according to Table 20 below are required to complete the delivery. For further details see corresponding Product Specification. Table 20

Option

Description

Product Spec.

382

DDU in separate box and cable to the cabinet

S4Cplus

686-689

Cables (7-30m) between DDU and SGs

S4Cplus

704

SMB box with cablings

S4Cplus

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

65

Description 1.11.5 Stationary Gun and Track Motion (SG + TM)

M1

M2

M1

CB1

D1

M2

CB2

D2

D1

option 382

D2

DDU-VW

(options 641-644)

SMB

M7C1B1.CFG

options 686-689 option 705

Figure 36 Configuration of Stationary Gun and Track Motion.

Options according to Table 21 below are required to complete the delivery. For further details see corresponding Product Specification. Note! Track Motion SMB box and cables to the control cabinet are included in the IRBT 6003S delivery. Table 21

Option

66

Description

Product Spec.

382

DDU in separate box and cable to the cabinet

S4Cplus

686-689

Cables (7-30m) between DDU and SG

S4Cplus

705

Cable between the cabinet and TM, and cable between TM and SG

S4Cplus

Incl. in TM delivery

SMB box with cablings Cable between DDU and TM

IRBT 6003S

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

Description 1.11.6 Robot Gun and Track Motion (RG + TM)

M1

M2

CB1

D1

M1

M2

CB2

D2

D1

option 382

D2

option 706 options 2063

DDU-VW SMB

M7C1B1.CFG

(options 641-644)

options 697-699

Figure 37 Configuration of Robot Gun and Track Motion.

Options according to Table 22 below are required to complete the delivery. For further details see corresponding Product Specification. Note! Track Motion SMB box, cables to the control cabinet and cable between SMB and DDU are included in the IRBT 6003S delivery. Table 22

Option

Description

Product Spec.

382

DDU in a separate box and cable to the cabinet

S4Cplus

697-699

Extended cables (7-30m) between DDU and RG

S4Cplus

706

Cable between the cabinet and TM, and between SMB and the manipulator

S4Cplus

2063

Parallel communication inclusive of Servo

IRB 6600

Incl. in TM delivery

SMB box with cablings Cable between DDU and TM

IRBT 6003S

625

Software SpotWare Servo

RobotWare Options

Product Specification IRB 6600 M2000

67

Description

1.12 Track Motion The robot can be supplied with a Track Motion, see Product Specification IRBT 6003S. For configuration and specification of hardware see Figure 38.

M1

M2

CB1

D1

M1

M2

CB2

D2

D1

option 2204 or 2200 or 383

option 383

D2

DDU-W

M7C1B1.CFG

TM delivery

(options 641-644)

Figure 38 Configuration of Track Motion.

Options according to Table 23 below are required to complete the delivery. For further details see corresponding Product Specification. Table 23

Option

68

Description

Product Spec.

383

DDU in a separate box and cable to the cabinet

S4Cplus

2204 or 2200

Cable from manipulator foot to SMB 7-axis

IRB 6600

TM delivery

Cable between DDU and TM

IRBT 6003S

Product Specification IRB 6600 M2000

Specification of Variants and Options

2 Specification of Variants and Options The different variants and options for the IRB 6600 are described below. The same numbers are used here as in the Specification form. For controller options, see Product Specification S4Cplus, and for software options, see Product Specification RobotWare Options.

1 MANIPULATOR VARIANTS 022 023 024 025 027

IRB 6600-175/2.8 IRB 6600-225/2.55 IRB 6600-175/2.55 IRB 6650-125/3.2 IRB 6650-200/2.75 Manipulator colour

330 Standard The manipulator is painted in ABB orange. 352 RAL code Colours according to RAL-codes.

Protection 035 Standard (IP 67) 036 Foundry Robot adapted for foundry or other harsh environments. The robot has the FoundryPlus protection which means that the whole manipulator is steam washable. The excellent corrosion protection is obtained by a special coating. The connectors are designed for severe environment, and bearings, gears and other sensitive parts are highly protected.

PROCESS CABLE PACKAGE For more information see chapter 1.9.2 DressPack options. 2204 Material Handling from base to axis 3 Requires Communication Parallel or Bus option 2063/2064. See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8, Table 9 and Table 10. 2205 Material Handling from axis 3 to axis 6 Requires Material Handling from base to axis 3, option 2204, and Communication Parallel or Bus, option 2063/2064. See Figure 39, and Description of DressPack on page 37, Table 2, Table 7, Table 8, Table 9 and Table 10. Product Specification IRB 6600 M2000

69

Specification of Variants and Options 2200 Spot Welding from base to axis 3 Requires Communication Parallel or Bus option 2063/2064. See Figure 40, and Description of DressPack on page 37, Table 3, Table 11, Table 12, Table 13, Table 14, Table 15 and Table 16. 2201 Spot Welding from axis 3 to axis 6 Requires Spot Welding from base to axis 3, option 2200, and communication Parallel or Bus, options 2063/2064. See Figure 40, and Description of DressPack on page 37, Table 3, Table 11, Table 12, Table 13, Table 14, Table 15 and Table 16.

option 2204 option 2205

From base to axis 3 From axis 3 to axis 6 Figure 39 Material Handling from base to axis 3, and Material Handling fromaxis 3 to axis 6.

option 2200

option 2201

Figure 40 Spot Welding from base to axis 3 , and Spot Welding from axis 3 to axis 6.

Communication 2063 Parallel Includes customer power CP, customer signals CS and Air for MH-process cable package. Includes CP, CS, Air and two Media hoses for SW-process cable package. 2064 Bus Includes CP, CS, Air and CAN/DeviceNet or Interbus for MH-process cable package. Includes CP, CS, Air, two Media hoses and CAN/DeviceNet or Interbus for SW-cable package.

70

2065 Extended Media SW Requires communication Parallel or Bus. Includes one Media hose. Only for option 2200 Spot Welding from base to axis 3, and option 2201 Spot Welding from axis 3 to axis 6. Product Specification IRB 6600 M2000

Specification of Variants and Options R1.SW1

R3.FB7

R1.SW2/3

R1.MP

R1.SMB

R1.PROC1 1 x 1/2”

R1.CP/CS

Figure 41 Location of MH connections on the foot.

R2.CP/CS R2.PROC1 1 x 1/2”

R2.MP 5/6

Figure 42 Location of MH connections on axis 3. R1.WELD 3 x 35mm2

R1.CP/CS R1.SW1

R3.FB7

R1.MP R1.SMB

R1.SW2/3

R1.PROC1-3 3 x 1/2”

Ext. Media SW (option 2065)

Figure 43 Location of SW connections on the base.

Product Specification IRB 6600 M2000

71

Specification of Variants and Options Connection to 056 Manipulator The signals are connected directly to the manipulator base to one heavy duty industrial housing with a Harting modular connector R1.CP/CS see Figure 41 and Figure 43). The cables from the manipulator base are not supplied. 057 Cabinet The signals CP/CS are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the controller. The cable between R1.CP/CS and the controller is supplied. For information about the limited number of signals available, see chapter 1.9.2 DressPack options.

Connection to cabinet (Cable lengths) Parallel/CANDeviceNet/Interbus/Profibus 675/660/670/665 7m 676/661/671/666 15m 678/663/673/668 30m Robot Servo Gun Extended/Stationary Servo Gun 699/686 697/687 698/689

7m 15m 30m

EQUIPMENT 691 Safety lamp A safety lamp with an orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode. The safety lamp is required on a UL/UR approved robot. 092 Fork lift device Lifting device on the manipulator for fork-lift handling. Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in order to use fork lift device. 087 Base plate Can also be used for IRB 7600. See chapter 1.3 Installation, for dimension drawing. 091 Brake release cover A cover for the break release buttons. 113 Cooling fan for axis 1 motor (IP 54) Cannot be combined with Cooling fan for axis 2 motor option 114. For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115). See Figure 44. Not for protection Foundry.

72

Product Specification IRB 6600 M2000

Specification of Variants and Options 114 Cooling fan for axis 2 motor (IP 54) For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115). Not for protection Foundry. 115 Cooling fan for axis 3 motor (IP 54) For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (option 113-115). See Figure 44. Not for protection Foundry. 088 Upper arm covers Included in protection Foundry. See Figure 45.

Option 115

Option 113

Figure 44 Cooling fan for axis 1 motor and axis 3 motor.

Option 088

Figure 45 Upper arm covers.

Product Specification IRB 6600 M2000

73

Specification of Variants and Options 089 Insulated tool flange The electrically insulated tool flange, according to European Standard EN 60204-1, withstands dangerous voltage (in case of an electrical fault in the spot welding equipment mounted on the Insulated tool flange) of 500V DC during 30 seconds in non water applications without passing it further to the electronics in the manipulator and the controller. Not available together with Protection Foundry, option 036. Connection holes and all dimensions are the same as for the standard tool flange except for the distance from c/c 5th axis to the end surface of the Insulated tool flange. The distance is 0,7 mm longer compared to the standard tool flange, see Figure 46. The countersinked holes for the fastening bolts to the gear box are larger, and the bolts are insulated from the tool flange, see Figure 46. Note The Insulated tool flange option can be ordered in combination with the Absolute Accuracy option, and the robot will then be factory calibrated. When the Insulated tool flange is mounted after the robot delivery, the robot must be re-calibrated for absolute accuracy. 200,7 0,3

Insulated tool flange Figure 46 Insulated tool flange (dimensions in mm).

CONNECTION KITS The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively. The kit consists of connectors, pins and sockets. 2220 R1.CP/CS and PROC1 For the Customer Power/Customer Signal connector and one Process connector on the manipulator base. Sockets for bus communication are included. 2221 R1.WELD and PROC2-4 For the Weld connector and three Process connectors on the manipulator base. 2222 R1.SW1 and SW2/3 For the position switch asis 1 connector and the position axis 2/3 connector on the manipulator base. 74

Product Specification IRB 6600 M2000

Specification of Variants and Options 2223 R3.FB7 For the 7-axis connector on the manipulator base. 2224 R2.CP/CS and PROC1 For the Customer Power/Customer Signal connector and one Process connector at axis 3. Pins for bus communication are included. 2225 R2.WELD and PROC2-4 For the Weld connector and three Process connectors at axis 3. 2070 WELD and PROC1-4 axis 6 Weld connector and four Process connectors at axis 6, the manipulator side.

POSITION SWITCHES Position switches indicating the position of the three main axes. Rails with separate adjustable cams are attached to the manipulator. The cams, which have to be adapted to the switch function by the user, can be mounted in any position in the working range for each switch. No machining operation of the cams is necessary for the adaptation, simple hand tools can be used. For axis 1, there are three redundant position zones available, each with two independent switches and cams. For axes 2 and 3, two chanals position zones are available, each with two independent switches and cams. For axis 1 it is possible to mount a second set of position switches, doubling the number of redundant zones to six. Each position zone consists of two switches mechanically operated by separate cams. Each switch has one normally open and one normally closed contact. See Product Specification S4Cplus. The design and components fulfill the demands to be used as safety switches. These options may require external safety arrangements, e.g. light curtains, photocells or contact mats. The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/ 3, (see Figure 41 and Figure 43), or to the controller. In the controller the signals are connected to screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08. Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and EN 60947-5-2. Connection to 075 Manipulator Connection on the manipulator base with one/two FCI 23-pin connector. 076 Cabinet Connection on the cabinet wall. Limit switch cables are included. Not available for second set of position switches, which have to be connected at the manipulator base. 071 Position switches axis 1 Three redundant position zones are available, each with two independent switches and cams. Product Specification IRB 6600 M2000

75

Specification of Variants and Options Connection of switches axis 1 (cable lengths) 078 7m 079 15m 081 30m 072 Position switches axis 2 Two redundant position zones are available, each with two independent switches and cams. 073 Position switches axis 3 Two redundant position zones are available, each with two independent switches and cams. Connection of switches axes 2 and 3 (cable lengths) 083 7m 084 15m 086 30m

Working Range Limit To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted by extra mechanical stops. Axis 1, 7,5 degrees 061 Four stops, two which allow the working range to be restricted in increments of 15o and two stops of 7,5o. 062 Axis 1, 15 degrees Two stops which allow the working range to be restricted in increments of 15o. 063 Axis 2 Six stops which allow the working range to be restricted in increments of 15o at both end positions. Each stop decreases the motion by 15o. 064 Axis 3 Six stops which allow the working range to be restricted in increments of 20o at both end positions. Each stop decreases the motion by 20o.

SPOTPACK Power Unit For more information see chapter 1.9.3 Power Unit 2087 Power unit AC welding type S 2088 Power unit AC welding type HS 2090 MFDC welding S and HS 2091 Forced air cooling 2092 Contactor for welding power

76

Product Specification IRB 6600 M2000

Specification of Variants and Options Weld power cable 2095 7m 2096 15m Process cable to Stationary Gun 2117

7m

2118

15m

2119

30m

Water and Air Fore more information see chapter 1.9.4 Water and Air Unit 2174 Water and Air unit type S 2175 Water and Air unit type HS 2177 Second water return 2192 Digital flow meter, one water return 2193 Digital flow meter, two water returns 2179 Pressure switch and regulator for air 2181 Electrical proportional valve for air Cable to split box 2183 7m 2184 15m 2185 30m

Product Specification IRB 6600 M2000

77

Specification of Variants and Options

78

Product Specification IRB 6600 M2000

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 Specification RobotWare Options. Robot Peripherals - Track Motion - Tool System - Motor Units - Spot welding system for transformer gun Tools Brake release box Includes six brake release buttons and 24V battery unit which can be connected to R1.BU on the manipulator frame. The brake release box can be ordered from ABB Automation Technology Products, Robotics, department S. Calibration Cube This calibration tool can be ordered from ABB Automation Technology Products, Robotics, department S.

Product Specification IRB 6600 M2000

79

Accessories

80

Product Specification IRB 6600 M2000

Index

4 Index A accessories 79 Active Brake System 6 C Collision detection 7 colours 69 cooling device 4 E Electronically Stabilised Path 7 emergency stop 8 enabling device 8 equipment mounting 25 permitted extra load 25 F fire safety 9 fork lift device 72

motion 31 mounting extra equipment 25 robot 10 mounting flange 28, 29 N noise level 4 O operating requirements 10 options 69 overspeed protection 7 P Passive Safety System 7 payload 10 position switches 8, 10, 75 protection 69 protection standards 10 R

hold-to-run control 9 hole configuration 11 holes for mounting extra equipment 26 humidity 10

range of movement 31 reduced speed 8 Robot Gun 63 Robot Gun and Track Motion 67 Robot Peripherals 79 robot tool flange 28, 29 robot versions 4

I

S

installation 10 Internal Safety Concept 8

safeguarded space stop 8 delayed 9 safety 6 Safety category 3 8 safety lamp 9, 72 Self Tuning Performance 7 service 30 Service Information System 6 space requirements 4 standards 6 Stationary and Robot Gun 64 Stationary Gun 62 Stationary Gun and Track Motion 66 structure 3

H

L lifting device 72 limit switches 8, 10, 75 load 10 load diagrams 13 M maintenance 30 manipulator colour 69 mechanical interface 28, 29

Product Specification IRB 6600 M2000

81

Index

T temperature 10 troubleshooting 30 Twin Stationary Guns 65 V variants 69 W weight 4 working space restricting 7, 10, 76 Z zone switches 8

82

Product Specification IRB 6600 M2000

Product Specification S4Cplus CONTENTS Page 1 Description ....................................................................................................................... 3 1.1 Structure.................................................................................................................. 3 1.2 Safety/Standards ..................................................................................................... 5 1.3 Operation ................................................................................................................ 7 Operator’s panel ..................................................................................................... 9 1.4 Memory .................................................................................................................. 11 Available memory .................................................................................................. 11 1.5 Installation .............................................................................................................. 12 Operating requirements.......................................................................................... 12 Power supply.......................................................................................................... 12 Configuration ......................................................................................................... 13 1.6 Programming .......................................................................................................... 13 Movements............................................................................................................. 14 Program management ............................................................................................ 14 Editing programs.................................................................................................... 15 Testing programs.................................................................................................... 15 1.7 Automatic Operation .............................................................................................. 15 1.8 The RAPID Language and Environment................................................................ 16 1.9 Exception handling ................................................................................................. 17 1.10 Maintenance and Troubleshooting ....................................................................... 17 1.11 Robot Motion........................................................................................................ 18 Motion concepts..................................................................................................... 18 Coordinate systems ................................................................................................ 18 Stationary TCP....................................................................................................... 20 Program execution ................................................................................................. 20 Jogging ................................................................................................................... 20 Singularity handling............................................................................................... 20 Motion Supervision................................................................................................ 20 External axes .......................................................................................................... 21 Big Inertia .............................................................................................................. 21 Soft Servo............................................................................................................... 21 1.12 External Axes ....................................................................................................... 21 1.13 I/O System ............................................................................................................ 23 Types of connection ............................................................................................... 24 ABB I/O units (node types) ................................................................................... 24 Distributed I/O ....................................................................................................... 25 Signal data.............................................................................................................. 26 Product Specification S4Cplus M2000/BaseWare OS 4.0

1

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

2

27 29 31 51

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

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

250 kg

Controller volume:

950 x 800 x 620 mm

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

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

Teach pendant

Operator´s panel

Mains switch

Disk drive

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

3

Description

Air distance to wall

200

200

800

Cabinet extension 800

Option 124

820 Extended cover

500

Option 123 250

950 980 *

Lifting points for forklift

500

* Castor wheels, Option 126 71

52 623

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

4

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.06/1999 Industrial robots, safety requirements ISO 9787 Manipulating industrial robots, coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC, Generic emission EN 61000-6-2 EMC, Generic immunity ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General Safety Requirements The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. The robot controller is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot. Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate.

Product Specification S4Cplus M2000/BaseWare OS 4.0

5

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

6

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

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

Hold-to-run Menu keys

Motion keys

Display

P5 P4 7 4 1

Window keys 1 2

P1

8 5 2 0

9 6 3

Joystick

Enabling device

P2 P3

Function keys

Emergency stop button Navigation keys

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

Information is presented on a display using windows, pull-down menus, dialogs and function keys. No previous programming or computer experience is required to learn how to operate the robot. All operations can be carried out from the teach pendant, which means that an additional keyboard is not required. All information, including the complete programming language, is in English or, if preferred, some other major language. (Available languages, see options on page 35). Display Displays all information during programming, to change programs, etc. 16 text lines with 40 characters per line. Motion keys Select the type of movement when jogging. Navigation keys Used to move the cursor within a window on the display and enter data. Menu keys Display pull-down menus, see Figure 4. Function keys Select the commands used most often. Window keys Display one of the robot’s various windows. These windows control a number of different functions: - Jog (manual operation) - Program, edit and test a program - Manual input/output management Product Specification S4Cplus M2000/BaseWare OS 4.0

7

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

Menu keys File

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

I/O list

1 0 1 0 1 1 13

di1 di2 grip1 grip2 clamp3B feeder progno 1

Menu 4(6)

Line indicator

Cursor

0

Function keys

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

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

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

MOTORS ON button and indicating lamp

Operating mode selector

Emergency stop If pressed in, pull to release

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

MOTORS ON Continuous light Fast flashing light (4Hz)

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

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

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

100%

Automatic mode

= Running production

Manual mode at reduced speed

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

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

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

9

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

10

Product Specification S4Cplus M2000/BaseWare OS 4.0

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

Flash disk memory 64/128 MB Boot 5 MB

System soft ware

Release storage 20 MB

Data

User RAPID program 5.5 MB

System data and user program 10 MB Power on restore

Power off store

Mass memory area available for the user

Figure 6 Available memory.

Product Specification S4Cplus M2000/BaseWare OS 4.0

11

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

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

IEC529 IP54

Explosive environments The controller must not be located or operated in an explosive environment. Ambient temperature Controller during operation with option 473 Controller during transportation and storage, for short periods (not exceeding 24 hours)

+5oC (41oF) to +45oC (113oF) +52oC (125oF) -25oC (13oF) to +42oC (107oF) up to +70oC (158oF)

Relative humidity Transportation, storage and operation

Max. 95% at constant temperature

Vibration Controller during transportation and storage Bumps Controller during transportation and storage

10-55 Hz: 55-150 Hz:

Max. ±0.15 mm Max. 20 m/s2

Max. 100 m/s2 (4-7 ms)

Power supply Mains voltage

12

Mains voltage tolerance

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

Mains frequency

48.5 to 61.8 Hz

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description Rated power: IRB 140, 1400, 2400 IRB 340, 14001, 24001,4400, 6400, 940 IRB 6600 IRB 7600 External axes cabinet Computer system backup capacity at power interrupt

4.5 kVA (transformer size) 7.8 kVA (transformer size) 6 kVA 7.1 kVA 7.2 kVA (transformer size) 20 sec (rechargeable battery)

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

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

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

1.6 Programming Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”.

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

13

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

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

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

The velocity may be specified in the following units: - mm/s - seconds (time it takes to reach the next programmed position) - degrees/s (for reorientation of the tool or for rotation of an external axis) Program management For convenience, the programs can be named and stored in different directories. The mass memory can also be used for program storage. These can then be automatically downloaded using a program instruction. The complete program or parts of programs can be transferred to/from the network or a diskette. The program is stored as a normal PC text file, which means that it can be edited using 14

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description a standard PC. Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, undo etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane. A robot position can easily be changed either by - jogging the robot with the joystick to a new position and then pressing the “ModPos” key (this registers the new position) or by - entering or modifying numeric values. To prevent unauthorised personnel from making program changes, passwords can be used. Testing programs Several helpful functions can be used when testing programs. For example, it is possible to - start from any instruction - execute an incomplete program - run a single cycle - execute forward/backward step-by-step - simulate wait conditions - temporarily reduce the speed - change a position - tune (displace) a position during program execution. For more information, see the User’s Guide and RAPID Reference Manual.

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

15

Description

Select program to run:

Front A Front B Front C

Other

Service

Figure 8 The operator dialogs can be easily customised.

A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution. You can also create special routines that will be automatically executed when the power is switched on, at program start and on other occasions. This allows you to customise each installation and to make sure that the robot is started up in a controlled way. The robot is equipped with absolute measurement, making it possible to operate the robot directly when the power is switched on. For your convenience, the robot saves the used path, program data and configuration parameters so that the program can be easily restarted from where you left off. Digital outputs are also set automatically to the value prior to the power failure.

1.8 The RAPID Language and Environment The RAPID language is a well balanced combination of simplicity, flexibility and powerfulness. It contains the following concepts: - Hierarchical and modular program structure to support structured programming and reuse. - Routines can be Functions or Procedures. - Local or global data and routines. - Data typing, including structured and array data types. - User defined names (shop floor language) on variables, routines and I/O. - Extensive program flow control. - Arithmetic and logical expressions. - Interrupt handling. - Error handling (for exception handling in general, see Exception handling). - User defined instructions (appear as an inherent part of the system). - Backward handler (user definition of how a procedure should behave when stepping backwards). - Many powerful built-in functions, e.g mathematics and robot specific. - Unlimited language (no max. number of variables etc., only memory limited). Windows based man machine interface with built-in RAPID support (e.g. user defined pick lists). 16

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description 1.9 Exception handling Many advanced features are available to make fast error recovery possible. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time. Examples: - Error Handlers (automatic recovery often possible without stopping production). - Restart on Path. - Power failure restart. - Service routines. - Error messages: plain text with remedy suggestions, user defined messages. - Diagnostic tests. - Event logging.

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

17

Description

1.11 Robot Motion Motion concepts QuickMoveTM The QuickMoveTM concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement. - No parameters have to be adjusted to achieve correct path, orientation and velocity. - Maximum acceleration is always obtained (acceleration can be reduced, e.g. when handling fragile parts). - The number of adjustments that have to be made to achieve the shortest possible cycle time is minimized. TrueMoveTM The TrueMoveTM concept means that the programmed path is followed – regardless of the speed or operating mode – even after an emergency stop, a safeguarded stop, a process stop, a program stop or a power failure. This very accurate path and speed is based on advanced dynamic modelling. Coordinate systems BaseWare includes a very powerful concept of multiple coordinate systems that facilitates jogging, program adjustment, copying between robots, off-line programming, sensor based applications, external axes co-ordination etc. Full support for TCP (Tool Centre Point) attached to the robot or fixed in the cell (“Stationary TCP”).

18

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

Tool Centre Point (TCP) Y

Tool coordinates Z

Base coordinates

X Y

Z

Axis 3

Axis 2

Y

Axis 3

Y

X Base coordinates

X

Axis 1

Z

X

Axis 1

Y Tool coordinates

Z Tool Centre Point (TCP)

Z

X

Z

Z User coordinates

Object coordinates

Y

Y

Y X

World coordinates X X 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 starting point for the other coordinate systems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop. The world coordinate system is also very useful when two robots work together or when using a robot carrier. The base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tool’s centre point and orientation. The user coordinate system specifies the position of a fixture or workpiece manipulator. The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator. The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed). Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool. If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined.

Product Specification S4Cplus M2000/BaseWare OS 4.0

19

Description Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object. Program execution The robot can move in any of the following ways: - Joint motion (all axes move individually and reach the programmed position at the same time). - Linear motion (the TCP moves in a linear path). - Circle motion (the TCP moves in a circular path). Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur. If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part. Jogging The robot can be manually operated in any one of the following ways: - Axis-by-axis, i.e. one axis at a time. - Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate systems mentioned above). - Reoriented around the TCP. It is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved. During manual operation, the current position of the robot and the external axes can be displayed on the teach pendant. Singularity handling The robot can pass through singular points in a controlled way, i.e. points where two axes coincide. Motion Supervision The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not OK. A further monitoring function, Collision Detection, is optional (see option “Load Identification and Collision Detection”).

20

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description External axes Very flexible possibilities to configure external axes. Includes for instance high performance coordination with robot movement and shared drive unit for several axes. Big Inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. For big, flexible objects it is possible to optimise the servo tuning to minimise load oscillation. Soft Servo Any axis (also external) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour.

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

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

Absolute position is accomplished by battery-backed resolver revolution counters in the serial measurement board (SMB). The SMB is located close to the motor(s) according to Figure 10. For more information on how to install an external axis, see the User’s Guide - External Axes. External axes for robot types IRB 4400 and IRB 6400X: When more than one external axis is used, the drive units for external axis 2 and upwards must be located in a separate cabinet as shown in Figure 10.

Product Specification S4Cplus M2000/BaseWare OS 4.0

21

Description External axes for robot types IRB 140, IRB 1400, and IRB 2400: When more than three external axes are used, the drive units for external axis 4 and upwards must be located in a separate cabinet as shown in Figure 10. External axes for robot types IRB 6600 and IRB 7600: The drive units for all external axes must be located in a separate cabinet as shown in Figure 10. Not supplied on delivery

Motor channel Serial signals for measurement and drive system

Single External Axes

SMB

Measurement System 1

Not supplied on delivery

Multiple External Axes

SMB

alt. Measurement System 2 Drive System 2

ABB Drives

Figure 10 Outline diagram, external axes.

22

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.13 I/O System A distributed I/O system is used, based on the fieldbus standard CAN/DeviceNet. This makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. Two independent CAN/DeviceNet buses allow various conditions of I/O handling. Both channels can be operating as master or slave. One bus, CAN1, is operating with fixed data rate, and the other, CAN2 (accessible by the software option I/O Plus), with different data rates. tap

thick/thin cable

S4Cplus

multiport-tap

R

trunk line

R node

thick/thin cable

node node

I/O CPU node

Daisy chain

node node

node

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

A number of different input and output units can be installed: - Digital inputs and outputs. - Analog inputs and outputs. - Gateway (slave) for Allen-Bradley Remote I/O. - Gateway (slave) for Interbus Slave. - Gateway (slave) for Profibus DP Slave. S4Cplus with the option I/O Plus can be configured for fieldbus units from other suppliers. For more details see the Product Specification RobotWare Options. The inputs and outputs can be configured to suit your installation: - Each signal and unit can be given a name, e.g. gripper, feeder. - I/O mapping (i.e. a physical connection for each signal). - Polarity (active high or low). - Cross connections. - Up to 16 digital signals can be grouped together and used as if they were a single signal when, for example, entering a bar code. - Sophisticated error handling. - Selectable “trust level” (i.e. what action to take when a unit is “lost”). Product Specification S4Cplus M2000/BaseWare OS 4.0

23

Description - Program controlled enabling/disabling of I/O units. - Scaling of analog signals. - Filtering. - Polarity definition. - Pulsing. - TCP-proportional analog signal. - Programmable delays. - Simulated I/O (for forming cross connections or logical conditions without need the for physical hardware). - Accurate coordination with motion. Signals can be assigned to special system functions, such as program start, so as to be able to control the robot from an external panel or PLC. The robot can function as a PLC by monitoring and controlling I/O signals: - I/O instructions are executed concurrent to the robot motion. - Inputs can be connected to trap routines. (When such an input is set, the trap routine starts executing. Following this, normal program execution resumes. In most cases, this will not have any visible effect on the robot motion, i.e. if a limited number of instructions are executed in the trap routine.) - Background programs (for monitoring signals, for example) can be run in parallel with the actual robot program. Requires Multitasking option, see Product Specification RobotWare. Manual functions are available to: - List all the signal values. - Create your own list of your most important signals. - Manually change the status of an output signal. - Print signal information on a printer. I/O signals can for some robots also be routed parallel or serial to connectors on the upper arm of the robot. Types of connection The following types of connection are available: - “Screw terminals” on the I/O units - Industrial connectors on cabinet wall - Distributed I/O-connections inside or on cabinet wall For more detailed information, see Chapter 2, Specification of Variants and Options. ABB 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. 24

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

Digital

Analog

DSQC

Option no.

In

Out

Digital I/O 24 VDC

328

20x

16

16

Internal/External1

Digital I/O 120 VAC

320

25x

16

16

Internal/External

Analog I/O

355

22x

AD Combi I/O

327

23x

16

16

Relay I/O

332

26x

16

16

Allen-Bradley Remote I/O Slave

350

241

1282

128

Interbus Slave

351

242-285

642

64

Profibus DP Slave

352

243-287

1282

128

100

100

Type of unit

Simulated I/O3 Encoder interface unit4 Encoder interface unit5

354

244

377

249

Voltage inputs

Voltage output

4

3 2

Current output

1

Power supply

Internal Internal/External1 Internal/External1

30

30

1

1. The digital signals are supplied in groups, each group having 8 inputs or outputs. 2. To calculate the number of logical signals, add 2 status signals for Allen-Bradley Remote I/O unit and 1 for Interbus and Profibus DP. 3. A non physical I/O unit can be used to form cross connections and logical conditions without physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit. 4. Dedicated for conveyor tracking only. 5. Only for PickMaster 4.0

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

CAN2 (option)

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

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

25

Description Signal data Permitted customer 24 V DC load Digital inputs 24 V DC

max. 7,5 A

(option 201/203) Optically-isolated Rated voltage: 24 V DC Logical voltage levels: “1” 15 to 35 V “0” -35 to 5 V Input current at rated input voltage: 6 mA Potential difference: max. 500 V Time delays: hardware 5−15 ms software ≤ 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 V Rated voltage 24 V DC Logical voltage levels: “1” 18 to 34 V “0” 1 Mohm Resolution: 0.61 mV (14 bits) Accuracy: +0.2% of input signal Analog outputs

Analog outputs

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

min. min.

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

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

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

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

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

27

Description Digital inputs

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

Analog output

TCP speed signal

1. Program can be decided when configuring the robot.

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

28

Product Specification S4Cplus M2000/BaseWare OS 4.0

Description

1.14 Communication The controller has three serial channels for permanent use - two RS232 and one RS422 Full duplex - which can be used for communication point to point with printers, terminals, computers and other equipment. For temporary use, like service, there are two more RS 232 channels. The serial channels can be used at speeds up to 19,200 bit/s (max. 1 channel with speed 19,200 bit/s). The controller has two Ethernet channels and both can be used at 10 Mbit/s or 100 Mbit/s. The communication speed is set automatically.

Temporary Main CPU console Ethernet 10 Mbit/s

Permanent Ethernet or serial Figure 12 Point-to-point communication.

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

Figure 13 Network (LAN) communication.

Product Specification S4Cplus M2000/BaseWare OS 4.0

29

Description

30

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

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

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

UNDERWRITERS LABORATORY 695 UL/CSA The robot is certified by Underwriters Laboratory to comply with the Safety Standard ANSI/UL 1740-1996 “Industrial Robots and Robotic Equipment” and CAN/CSA Z 434-94. UL/UR certification is required by law in some US states and Canada. UL (UL/CSA) means certification of complete product and UR (UL recognized Component) means certification of component or not complete product. Safety lamp (691) Door interlock (145 or 142) Operating mode selector standard 2 modes (193) are mandatory. Not with Cabinet height 950 mm no cover (122), Cabinet height 1200 mm (123), Cabinet height 1750 mm (124), Cabinet variant Prepared for Arcitec (112), Mains connection type CEE17 connector (132, 133), Service outlet type 230V Europe (412). 696 UR (UL Recognized) The robot is certified by Underwriters Laboratory to comply with the Safety Standard UL 1740 “Industrial Robots and Robotic Equipment”. UL/UR certification is required by law in some US states and Canada. UL (UL listed) means certification of complete product and UR (UL Recognized Component) means certification of component or not complete product. Safety lamp (691), Door interlock (145 or 142), Operating mode selector standard 2 modes (193) are mandatory. Not with Cabinet variant Prepared for Arcitec (112), Mains connection type CEE17 connector (132, 133), Service outlet type 230V Europe (412).

Product Specification S4Cplus M2000/BaseWare OS 4.0

31

Specification of Variants and Options 2 CONTROL SYSTEM CABINET Variant 111 Standard cabinet with upper cover. 112 Prepared for Arcitec Rotary switch 80A (143) and Circuit breaker standard (147) and Arcitec 4.0 (556) are mandatory. Not with Wheels (126) or Mains connection type CEE17 connector (132, 133) or 6HSB (134) or Mains switch Flange disconnector (142) or Servo disconnector (144) or UL (695) or UR (696). Cabinet Height (wheels not included in height) 121 Standard cabinet 950 mm with upper cover. 122 Standard cabinet 950 mm without upper cover. To be used when cabinet extension is mounted on top of the cabinet after delivery. Not with Door interlock (145) or UL (695) or UR (696). 123 Standard cabinet with 250 mm extension. The height of the cover increases the available space for external equipment that can be mounted inside the cabinet. Not with UL (695). 124 Standard cabinet with 800 mm extension. The extension is mounted on top of the standard cabinet. There is a mounting plate inside. (See Figure 14). The cabinet extension is opened via a front door and it has no floor. The upper part of the standard cabinet is therefore accessible. Not with UL (695) and Servo disconnector (144). 20

665

9 (x4)

690

730

20 705 Figure 14 Mounting plate for mounting of equipment (dimensions in mm)

126 Cabinet on wheels. Increase the height by 30 mm. Not with Prepared for Arcitec (112). 32

Product Specification S4Cplus M2000/BaseWare OS 4.0

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

M4 (x4) M8 (x4) 45o

Required depth 200 mm

196

193

180 224 240

223

70

62 140

96 Holes for flange

184 200 Holes for operator’s panel

External panel enclosure (not supplied)

Holes for teach pendant holder

Teach pendant connection

Connection to the controller

90

5 (x2)

155

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

Product Specification S4Cplus M2000/BaseWare OS 4.0

33

Specification of Variants and Options

M5 (x4) for fastening of box

337

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

OPERATOR’S PANEL CABLE 185 15 m 186 22 m 187 30 m

DOOR KEYS 461 462 463 464 466

Standard Doppelbart Square outside 7 mm EMKA DB Locking cylinder 3524

OPERATING MODE SELECTOR 193 Standard, 2 modes: manual and automatic. 191 Standard, 3 modes: manual, manual full speed and automatic. Does not comply with UL and UR safety standards.

CONTROLLER COOLING 472 Ambient temperature up to 45oC (113oF) Standard design. The computer unit is provided with a passive heat exchanger (cooling fins on the rear part of the box). 473 Ambient temperature up to 52oC (125oF) The computer unit is provided with an active Peltier cooling equipment (replaces the cooling fins from option 472.

34

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options TEACH PENDANT 601 Teach pendant with back lighting, connection cable 10 m. Teach pendant language: 611 612 613 614 615 616 617 618 619 620 621 622

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

606 10 m An extension cable can be connected between the controller and the teach pendant. The total length of cable between the controller and the teach pendant should not exceed 30 m. Note that the length of the optional operator’s panel cable must be included in the limitation. 607 20 m

MAINS VOLTAGE The control system can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible. 151 152 153 154 155 156 157 158

200V 220V 400V 440V 475V 500V 525V 600V For all robots except for IRB 6600/7600 the voltage range must be specified. This gives the possibility to select between three different transformers.

162 Voltage range 200, 220, 400, 440V 163 Voltage range 400, 440, 475, 500V 164 Voltage range 475, 500, 525, 600V The robots IRB 7600 (all versions) and IRB 6650-125/3.2 are supplied with an external transformer, see Figure 17, except for the option 155. The mains voltage 475V does not need any drive system transformer.

Product Specification S4Cplus M2000/BaseWare OS 4.0

35

Specification of Variants and Options

560

300

398

Figure 17 Transformer unit (dimensions in mm).

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 CEE17-connector 32 A, 380-415 V, 3p + PE (see Figure 18). Not with Flange disconnector (142) or UL/UR (695/696) or Service outlet power supply (432). Not available for IRB 6600/7600. Figure 18 CEE male connector.

133 32 A, 380-415 V, 3p + N + PE (see Figure 18). Not with Flange disconnector (142) or UL/UR (695/696). Not available for IRB 6600/7600. 134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640. 35 A, 600 V, 6p + PE (see Figure 19). Cannot be combined with Flange disconnector (142).

Figure 19 DIN male connector.

MAINS SWITCH 141 Rotary switch 40 A in accordance with the standard in section 1.2 and IEC 337-1, VDE 0113. Customer fuses for cable protection required. 142 Flange disconnector in accordance with the standard in section 1.2. Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt capacity 14 kA. 0058 Flange disconnector in accordance with the standard in section 1.2. Includes door interlock for flange disconnector and a 20A circuit breaker with interrupt 36

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options 143 144

145 147

capacity 65 kA at 400V, 25 kA at 600V. Rotary switch 80 A. Customer fuses for cable protection required. Included in the option Prepared for Arcitec (112). Servo disconnector. This option adds a rotary switch 40 A to the two contactors in the AC power supply for the drive system. The handle can be locked by a padlock, e.g. in an off position. Door interlock for rotary switch. Included in the options UL/CSA/UR (695, 696) and Servo disconnector (144). Circuit breaker for rotary switch. A 16A (option 163 and 164) or 25A (option 162) circuit breaker for short circuit protection of mains cables in the cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660. Interrupt capacity 6 kA.

Product Specification S4Cplus M2000/BaseWare OS 4.0

37

Specification of Variants and Options I/O INTERFACES The standard cabinet can be equipped with up to four I/O units. For more details, see page 23. X6 (CAN 1.2) X7 (CAN 1.3)

X8 (CAN 2)

Base Connector Unit DSQC 504 CAN 1 NS MS

Ph.5-Pol

X7 CAN 1.3

X10 SIO1

X9 SIO2

Test

X15 CAN 1.1

X12 PANEL BOARD

X20 DRIVE SYSTEM 2

R E L Ä

Ph.5-Pol

8-Pol

DB-44

9-Pol D-sub

X1 I/O COMPUTER

X11 CONSOLE

9-Pol D-sub

X15 (CAN 1.1)

Ph.5-Pol

15-Pol D-sub

9-Pol D-sub

X9 (COM3, RS422)

X8 CAN 2

Ph.5-Pol

X5 MEASUREMENT SYSTEM 2

X2 AXIS COMPUTER

X6 CAN 1.2

25-Pol D-sub

X10 (COM2, RS232)

CAN 2 NS MS

X4 MEASUREMENT SYSTEM 1

15-Pol D-sub

15-Pol D-sub

15-Pol Female FCI X3 DRIVE SYSTEM 1

X14 EXPANSION BOARD

15-Pol Male FCI

25-Pol D-sub

X13 POWER SUPPLY

Cabinet view from above I/O Units (X4)

Computer system (COM1, RS232) XT 31 (24V I/O)

Panel Unit WARNING DSQC 509

Manipulator connections

X1-X4 Safety Signals

115/230 VAC

REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN

MS NS

ES1 ES2 GS1 GS2 AS1 AS2

X3 X1-X4 CUSTOMER CONNECTIONS

X1

X2

X4

POWER UNIT / POWER CONTROL X5 X8 1

XP5

XP58

1

1

1

X9, BASE CONN UNIT

XP6

1

RL2

X7, TEACH PENDANT

XT21

Connection to Position switches

X6, CONTROL PANEL

RL1

XP8

Connection to Customer power Customer signals Figure 20 I/O unit and screw terminal locations.

38

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options 201 Digital 24 VDC I/O: 16 inputs/16 outputs. 202 Analog I/O: 4 inputs/4 outputs. 203 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 204 Digital 120 VAC I/O 16 inputs/16 outputs. 205 Digital I/O with relay outputs: 16 inputs/16 outputs. Relay outputs to be used when more current or voltage is required from the digital outputs. The inputs are not separated by relays. Connection of I/O 251 Internal connection (options 201-204, 221-224, 231-234, 251-254, 261-264) The signals are connected directly to screw terminals on the I/O units in the upper part of the cabinet (see Figure 20). 252 External connection The signals are connected via 64-pole standard industrial connector in accordance with DIN 43652. The connector is located on the left-hand side of the controller. Corresponding customer part is included. 208 Prepared for 4 I/O units The internal CAN/Devicenet cabling to the I/O units exists in two versions, one for up to two I/O units and one for up to four I/O units. The versions are selected to match the number of ordered I/O units. By this option it is possible to get the four unit version even if less than three I/O units are ordered.

SAFETY SIGNALS 206 Internal connection The signals are connected directly to screw terminals in the upper part of the cabinet (see Figure 20). 207 External connection The signals are connected via 64-pole standard industrial connector in accordance with DIN 43652. The connector is located on the left-hand side of the controller. Corresponding customer part is included.

FIELD BUS AND COMMUNICATION 245 CAN/DeviceNet Connection on the left side to two 5-pole female connectors in accordance with ANSI. (Male connectors are supplied). 240 LAN/Ethernet RJ45 connector to be used for LAN connector. (When the connector is not used, a protective hood covers it). 246 Profibus DP Master/Slave The hardware of the Profibus-DP field bus consists of a master/slave unit, DSQC 510, and distributed I/O units, called slave units. The DSQC 510 unit is mounted in the S4Cplus computer system where it is connected to the PCI bus while the slave units are attached to the field bus network. Product Specification S4Cplus M2000/BaseWare OS 4.0

39

Specification of Variants and Options The slave units can be I/O units with digital and/or analogue signals. They are all controlled via the master part of the DSQC 510 unit. The slave part of the DSQC 510 is normally controlled by an external master on a separate Profibus-DP network. This network is a different one than the network holding the slave units for the master part of the board. The slave part is a digital input and output I/O unit with up to 512 digital input and 512 digital output signals. The signals are connected to the board front (two 9-pole D-sub). 19 units (internal or external) can be connected to the cabinet. Profibus DP M/S CFG Tool (option 270) is required when setting up the master part or when changing the number of signals for the slave part. For more information see Product Specification RobotWare Options. 247/248 Interbus Master/Slave The hardware of the Interbus field bus consists of a Master/Slave unit (DSQC512/529) and distributed I/O units. The master and the slave units are two separate boards connected by a flat cable. The DSQC512/529 unit is connected to the S4Cplus robot controller PCI bus while the I/O units are attached to the field bus net. The I/O units may be digital or analog modules. They are all controlled by the master part of the DSQC512/529 unit. The slave part of the DSQC512/529 unit is normally controlled by an external master on a separate Interbus network. This network is a different one than the network hold ing the I/O units for the master part of the board. The slave part is a digital in- and out put I/O unit with up to 160 digital in- and 160 digital out signals. Two variants are available: 247 for optical fibre connection (DSQC512) 248 for copper wire connection (DSQC529) Interbus M/S CFG Tool (option 271) is required when setting up the master part or when changing the number of signals for the slave part. For more information see Product Specification RobotWare Options.

GATEWAY UNITS For more details, see I/O System on page 23. 241 Allen-Bradley Remote I/O Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the number of I/O units that can be mounted in cabinet by one. The field bus cables are connected directly to the A-B Remote I/O unit in the upper part of the cabinet (see Figure 20). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included. 242 Interbus Slave Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC equipped with an InterBus interface. The unit reduces the number of I/O units that can be mounted in the cabinet by one. The signals are connected directly to the InterBus slave unit (two 9-pole D-sub) in the upper part of the cabinet. 40

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options 243 Profibus DP Slave Up to 128 digital inputs and 128 digital outputs can be transferred serially to a PLC equipped with a Profibus DP interface. The unit reduces the number of I/O units that can be mounted in the cabinet by one. The signals are connected directly to the Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet. 244 Encoder interface unit for conveyor tracking (DSQC 354) Conveyor Tracking, RobotWare option 540, is the function whereby the robot follows a work object which is mounted on a moving conveyor. The encoder and synchronization switch cables are connected directly to the encoder unit in the upper part of the cabinet (see Figure 20). Screw connector is included. This option is also required for the function Sensor Synch, RobotWare option 547. 249 Encoder interface unit for conveyor tracking (DSQC 377) Only available for IRB 140 and IRB 340, required for PickMaster 4.0. Physically similar to option 344.

EXTERNAL I/O UNITS I/O units can be delivered separately. The units can then be mounted outside the cabinet or in the cabinet extension. These are connected in a chain to a connector (CAN 3 or CAN 2, see Figure 20) in the upper part of the cabinet. Connectors to the I/O units and a connector to the cabinet (Phoenix MSTB 2.5/xx-ST-5.08), but no cabling, is included. Dimensions according to Figure 21 and Figure 22. For more details, see I/O System on page 23. 221 Digital I/O 24 V DC: 16 inputs/16 outputs. 222 Analog I/O. 223 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 224 Digital I/O 120 V AC: 16 inputs/16 outputs. 225 Digital I/O with relay outputs: 16 inputs/16 outputs.

EXTERNAL GATEWAY UNITS 231 Allen Bradley Remote I/O 232 Interbus Slave 233 Profibus DP Slave 234 Encoder interface unit DSQC 354 for conveyor tracking 235 Encoder interface unit DSQC 377 for conveyor tracking (IRB 140 and IRB 340 only)

Product Specification S4Cplus M2000/BaseWare OS 4.0

41

Specification of Variants and Options

EN 50022 mounting rail

195

203

49

Figure 21 Dimensions for units 221-225.

EN 50022 mounting rail

170

49

115 Figure 22 Dimension for units 231-234.

EXTERNAL AXES IN ROBOT CABINET (not available for IRB 340, IRB 6400PE, IRB 6600, IRB 7600) It is possible to equip the controller with drives for external axes. The motors are connected to a standard industrial 64-pin female connector, in accordance with DIN 43652, on the left-hand side of the cabinet. (Male connector is also supplied.) 391 Drive unit C The drive unit is part of the DC-link. Recommended motor type see Figure 23. Not available for IRB 640. 392 Drive unit T The drive unit is part of the DC-link. Recommended motor type see Figure 23. Not available for IRB 640, 6400R. 397 Drive unit U The drive unit is part of the DC-link. Recommended motor types see Figure 23. Not available for IRB 4400, 6400S, 6400PE, 640. For IRB 140, 1400 and 2400 the option consists of a larger transformer, DC link DC4U with integrated U drive unit and one extra axis computer with its connection board. 42

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options No cabling from the drive unit U to cabinet wall is included. For IRB 6400R the option consists of a DC link DC4U with integrated U drive unit with cabling to the cabinet wall. 393 Drive unit GT A separate drive unit including two drives. Recommended motor type see Figure 23. Not available for IRB 4400, 6400R, 6400S 396 Prepared for drives GT The same as 393 but without the GT drive module. The preparation includes; larger transformer, larger DC link DC2, and one additional axis computer with its connection board. Not available for IRB 4400, 640, 6400R, 6400S 398 Prepared for drives GT The same as 396 but without additional axes computer and connection board. 399 Prepared for drives GU The same as 396 but intended for a GU drive module. The preparation includes: larger transformer, larger DC link DC4, and one additional axis computer with its connection board. Not available for IRB 4400, 640, 6400R, 6400S. 394 Drive unit T+GT A combination of 392 and 393. Not available for IRB 4400, 640, 6400R, 6400S 395 Drive unit C+GT A combination of 391 and 393 Not available for IRB 4400, 640, 6400R, 6400S 365 Trackmotion A special wiring for the three motor combination 394 (IRB 140, 1400, 2400 only) to be used when axis 7 is intended for an ABB Trackmotion. The drive unit in the DC link and the Trackmotion measurement board is then connected to the robot axes computer 1 while the drive unit and the measurement board for motor 8 and 9 is connected to axes computer 2. All motor power wiring is routed to one common connector, XS7. 701-706 Servo gun interfacing (IRB 6400R, IRB 6600 and 7600) For further information see the Product Specification IRB 6400R chapter Servo Gun or IRB 6600 chapter Servo Gun (overview), and the Product Specification RobotWare Options (function description). 701 Stationary gun (SG) IRB 6400R The option consists of an encapsulated Serial Measurement Board (SMB) and cabling inside the controller. The cabling between SMB and the controller is selected in the option range 686689. Drive unit 397 is required. IRB 6600/7600 The option includes cabling inside the controller and the manipulator, and a 7m resolver cable between the manipulator and the welding gun pedestal. The customer connector to this cable should be an 8-pin Burndy, wired according to Motor Unit Product Specification S4Cplus M2000/BaseWare OS 4.0

43

Specification of Variants and Options specification. The cable between the controller DDU and the welding gun pedestal is selected in the option range 686-687 (different lengths). The customer connector to this cable should be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600). Besides the necessary motor wiring, it also contains 12 wires for gun I/O, accessible on screw terminals in the cabinet. Drive unit 381 (DDU-V) must be selected. 702 Robot Gun (RG) IRB 6400R The option consists of an encapsulated SMB and cabling inside the controller. It also includes bracket for 6400R foot mounting of the SMB box, and cabling between the SMB box and the manipulator. The cabling between SMB and the controller is selected in th option range 681-684. Drive unit option 397 is required. IRB 6600/7600 The option includes cabling inside the controller and the manipulator. The cable between the controller and the manipulator is selected in the option range 697-699. Besides the necessary motor wiring the cable also contains 22 wires for gun I/O and CAN/DeviceNet fieldbus. The I/O wiring is accessible on screw terminals in the cabinet. Drive unit 381 (DDU-V) must be selected. 703 One SG and one RG IRB 6400R The option is a combination of 701 and 702. A distributed drive unit (DDU) controls the SG motor. The cabling between the SG SMB and the controller is selected in the option range 686-689, and the cabling between the RG SMB and the controller is selected in the option range 681-684. Drive unit options 397 (for the RG) and 380 (for the SG) are required. IRB 6600/7600 The option includes cabling inside the controller and the manipulator. The cable between the controller and the welding gun pedestal is selected in the option range 686-687. The customer connector to this cable should be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/ 7600). Besides the necessary motor wiring it also contains 12 wires for gun I/O, accessible on screw terminals in the cabinet. The cable between the controller and the manipulator is selected in the option range 697-699. Besides the necessary motor wiring the cable also contains 22 wires for gun I/O and CAN/DeviceNet fieldbus. The option also consists of an SMB box for two resolvers, a serial cable between the box and the controller (the same length as 641-642), and two resolver cables, one 1.5m for the RG and one 7m for the SG. The customer connector to the SG cable should be an 8-pin Burndy, wired according to the Motor Unit specification. The SMB box should be mounted close to the manipulator foot. Dimensions and mounting information can be found in the Product Specification Motor Unit. Drive unit 382 (DDU-VW) must be selected. 44

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options 704 Twin SG IRB 6400R The option is a combination of two options 701. A distributed drive unit controls the second SG motor. The cabling between the SG SMBs and the controller is selected in the option range 686-689. Drive unit options 397 (for one SG) and 380 (for the second SG) are required. IRB 6600/7600 The option includes cabling inside the controller. The two cables between the controller and the pedestals are selected in the option range 686-687. Customer connectors to the cables should be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600). Besides the necessary motor wiring, the cables also contain 12 wires for gun I/O, accessible on screw terminals in the cabinet (SG axis 7), or on the Multi connector inside (SG axis 8) the DDU. The option also consists of an SMB box for two resolvers, a serial cable between the box and the controller (the same length as 686-687), and two 7m resolver cables. The customer connector to the SG cable should be an 8-pin Burndy, wired according to the Motor Unit specification.The SMB box should be mounted close to the manipulator foot. Dimensions and mounting information can be found in the product Specification Motor Unit. Drive unit 382 (DDU-VW) must be selected. 705 SG and Track Motion (T) IRB 6400R The option is a combination of 701 and a track motion IRBT 6002S controlled by a distributed drive unit. The cabling between the SG SMB and the controller is selected in the option range 686-689. Drive unit options 397 (for the SG) and 380 (for the T) are required. IRB 6600/7600 The option includes cabling inside the controller. The cable between the controller and the welding gun pedestal is selected in the option range 686-687. The customer connector to the cable should be of Industrial Multi-connector type, corresponding to the manipulator CP/CS (see Product Specification IRB 6600/7600). Besides the necessary motor wiring the cable also contains 12 wires for gun I/O, accessible on screw terminals in the cabinet. The resolver cable for the SG must be ordered together with the Track Motion. The customer connector to the cable should be an 8-pin Burndy, wired according to the Motor Unit specification. The SMB box and the power cable between the controller and the Track Motion are included in the Track Motion delivery. The serial measurement cable between the controller and the Track Motion are included in option 705 (length according to 641642). Drive unit 382 (DDU-VW) must be selected. Product Specification S4Cplus M2000/BaseWare OS 4.0

45

Specification of Variants and Options 706 RG and T IRB 6400R The option is a combination of 702 and a track motion IRBT 6002S controlled by a distributed drive unit. The cabling between the RG SMB and the controller is selected in the option range 681-684. Drive unit options 397 (for the SG) and 380 (for the T) are required. IRB 6600/7600 The option includes cabling inside the controller. The RG cable between the controller and Track Motion is selected in the option range 697-699 except for the track motor cable which is included in the Track Motion delivery. Besides the necessary motor wiring, the RG cable also contains 22 wires for gun I/O and CAN/DeviceNet fieldbus. The option also consists of a 1.5m resolver cable for the RG to be connected to the Track Motion mounted SMB box. Drive unit 382 (DDU-VW) must be selected.

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

EXTERNAL AXES - SEPARATE CABINET (not available for IRB 340, IRB 6400PE) An external cabinet can be supplied when there is not space enough in the standard cabinet. The external cabinet is connected to one Harting connector (cable length 7 m) on the left-hand side of the robot controller. Door interlock, mains connection, mains voltage and mains filter according to the robot controller. One transformer and one mains switch are included. 371/372 373 374 375

46

Drive unit GT, for 4 or 6 motors. Recommended motor types see Figure 23. Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 23. Drive unit GT + ECB Drive unit GT + GT + ECB

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options

Drive unit identity

Motor max current Arms

Drive unit rated current Arms

Suitable motor type

W

11.5-57

30

XL

V

5.5-26

14.5

XL

U

11 - 55A

24A

M, L

G

6 - 30A

16A

S, M, L

T

7.5-37

20

S, M, L, XL

E

4 - 19A

8,4A

S, M

C

2,5 - 11A

5A

S

B

1,5 - 7A

4A

S

Figure 23 Motor selection table. Motor types according to external axes Motor Unit.

380 Drive unit DDU-U A separate box (H=500mm W=300mm D=250mm) including a DC link DC4 and a drive unit GU where the U part is used (the G part is not connected). The DDU-U is operated from an additional axis computor, included in the option. DDU-U is mainly intended for Servo Gun solutions according to options 703-706 and is available for IRB 4400 and 6400R. 381 Drive unit DDU-V (IRB 6600/7600) 382 Drive unit DDU-VW (IRB 6600/7600) 383 Drive unit DDU-W (IRB 6600/7600) A separate box (H=500mm, W=300mm, D=250mm) including a DC link DC5 and a drive unit VW. The box has 4 keyholes on the back of the encapsulation for fastening. Connection cabling (length 5m) to the controller is included. The DDU-VW is operated from an additional axis computer included in the option, while the DDU-V and -W are operated from the basic robot axes computer. The options also include appropriate cabling inside the manipulator for different resolver configurations, see Product Specification IRB 6600, chapter Servo Gun. E.g. 7 axes applications utilise the built in 7 resolver SMB. The DDU-V and VW are mainly intended for Servo Gun solutions according to options 701-706. The DDU-W is intended for a Track Motion without Servo Gun.

Product Specification S4Cplus M2000/BaseWare OS 4.0

47

Specification of Variants and Options EQUIPMENTManipulator cable, external connectors 653 Standard Cable length 641 642 643 644 649

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

657 External (not for the SA-version i.e. WashDown) 658 Internal Protection for manipulator cable 845 Each unit length is 2 m. Totally 40 m protection can be specified.

SERVICE OUTLET Any of the following standard outlets with protective earthing can be chosen for maintenance purposes. The maximum load permitted is 500 VA (max. 100 W can be installed inside the cabinet). 411 120 V in accordance with American standard; single socket, Harvey Hubble. 412 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for EU countries.

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

MEMORY Removable mass memory 320 Floppy drive The disk drive normally works well at temperatures up to 40oC (104oF). The disk drive

48

Product Specification S4Cplus M2000/BaseWare OS 4.0

Specification of Variants and Options will not deteriorate at higher temperatures but there will be an increase in the number of reading/writing problems as the temperature increases. Extended mass memory 310 Flash disc 128 Mb. Standard is 64 Mb

Product Specification S4Cplus M2000/BaseWare OS 4.0

49

Specification of Variants and Options

50

Product Specification S4Cplus M2000/BaseWare OS 4.0

Index

3 Index A absolute measurement 16 Allen-Bradley Remote I/O 23, 25, 40 analog signals 23, 27 automatic operation 15 B backup computer system backup 13 memory 11 base coordinate system 19 Big Inertia 21 bumps 12 C cabinet wheels 32 CAN/DeviceNet 39 collision detection 6 communication 29 concurrent I/O 24 configuration 12, 13, 23 connection 48 mains supply 36 cooling device 3 coordinate systems 18 cross connections 23 cursor 7

event routine 16 explosive environments 12 extended memory 11 external axes 21 external panel 33 F fire safety 6 flash disk memory 11 fly-by point 14 function keys 7 H hold-to-run 8 hold-to-run control 6 humidity 12 I I/O units 24 I/O-system 23 incremental jogging 20 inputs 23 installation 12 Interbus Slave 23, 25, 40 interrupt 24 J jogging 20 joystick 8

D

L

diagnostics 17 digital signals 23, 26 display 7 distributed I/O 25

LAN/Ethernet 39 language 13 lighting connection 48 teach pendant 35

E editing position 15 programs 15 emergency stop 6, 7 emergency stop button 8 enabling device 5, 8 display 7 Encoder interface unit 25, 41

M mains supply 36 mains switch 36 mains voltage 35 maintenance 17 manipulator cable 48 length 48 protection 48

Product Specification S4Cplus M2000/BaseWare OS 4.0

51

Index

mass memory 11 memory backup 11 extended 11 flash disk 11 mass storage 11 RAM memory 11 menu keys 7 mirroring 15 motion 18 motion keys 7 motion performance 18 Motion Supervision 20 Multitasking 24 N navigation keys 7 noise level 3 O object coordinate system 19 operating mode 9 operating mode selector 9, 34 operating requirements 12 operation 7 operator dialogs 13 operator’s panel 9, 33 options 31 outputs 23 over-speed protection 6 P password 13, 15 performance 18 PLC functionality 24 position editing 15 execution 20 programming 14, 19 position fixed I/O 24 power supply 12 production window 15 Profibus 39 Profibus DP Slave 23, 25, 41 program editing 15 testing 15 52

programming 13 protection standards 12 Q QuickMove 18 R RAPID Language 16 reduced speed 5 S safe manual movements 6 safeguarded space stop 6 delayed 6 safety 5 safety lamp 6 serial communication 29 service 17 service outlets 48 signal data 26 singularity handling 20 Soft Servo 21 space requirements 3 standards 5 stationary TCP 20 stop point 14 structure 3 system signals 27 T TCP 19 teach pendant 7 cable 35 language 35 lighting 35 temperature 12 testing programs 15 tool coordinate system 19 tool’s centre point 19 trap routines 24 troubleshooting 17 TrueMove 18 U user coordinate system 19 user-defined keys 8 Product Specification S4Cplus M2000/BaseWare OS 4.0

Index V variants 31 vibration 12 volume 3 W window keys 7 windows 7 working space restricting 6 world coordinate system 19

Product Specification S4Cplus M2000/BaseWare OS 4.0

53

Index

54

Product Specification S4Cplus M2000/BaseWare OS 4.0

Product Specification RobotWare Options 3HAC 9218-1/Rev.2 BaseWare OS 4.0

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

© ABB Automation Technology Products AB Robotics Article number: 3HAC 9218-1 Rev.2 Issue: BaseWare OS 4.0 ABB Automation Technology Products AB, Robotics SE-721 68 Västerås Sweden

Product Specification RobotWare Options CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 BaseWare Options ........................................................................................................... 5 [544] Absolute Accuracy ....................................................................................... 5 [541] Load Identification and Collision Detection (LidCode) .............................. 7 [542] ScreenViewer ............................................................................................... 9 [532] Multitasking ................................................................................................. 11 [531] Advanced Motion ......................................................................................... 12 [530] Advanced Functions ..................................................................................... 14 [537] Developer’s Function ................................................................................... 19 [558] Discrete Application ..................................................................................... 22 [540] Conveyor Tracking ....................................................................................... 23 [533] Electronically Linked Motors ....................................................................... 24 [547] Sensor Synchronization ................................................................................ 25 [539] Sensor Interface ............................................................................................ 26 [561] Servo Tool Control ....................................................................................... 27 [631] Servo Tool Change ....................................................................................... 29 [535] RAP Communication ................................................................................... 31 [543] Ethernet Services .......................................................................................... 32 [534] FactoryWare Interface .................................................................................. 33 [271] Interbus Configuration Tool ......................................................................... 34 [270] Profibus DP Configuration Tool ................................................................... 35 [538] I/O Plus ......................................................................................................... 36 3 ProcessWare..................................................................................................................... 37 [551] ArcWare ........................................................................................................ 37 [552] ArcWare Plus ................................................................................................ 40 [556] Arcitec .......................................................................................................... 41 [553] SpotWare ...................................................................................................... 42 [554] SpotWare Plus .............................................................................................. 44 [625] SpotWare Servo ............................................................................................ 46 [626] SpotWare Servo Plus .................................................................................... 49 [569] DispenseWare ............................................................................................... 51 [571] PalletWare .................................................................................................... 53 4 Index ................................................................................................................................. 57

Product Specification RobotWare Options for BaseWare OS 4.0

1

Product Specification RobotWare Options

2

Product Specification RobotWare Options for BaseWare OS 4.0

Introduction

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

Product Specification RobotWare Options for BaseWare OS 4.0

3

Introduction

4

Product Specification RobotWare Options for BaseWare OS 4.0

[544] Absolute Accuracy

2 BaseWare Options [544] Absolute Accuracy Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute accuracy of better than ±1 mm in the entire working range. The user is supplied with robot calibration data (error parameter file) and a certificate that shows the performance (Birth Certificate). The difference between an ideal robot and a real robot can be typically 8 mm, resulting from mechanical tolerances and deflection in the robot structure. Absolute Accuracy option is integrated in the controller algorithms for compensation of this difference, and does not need external equipment or calculation. Features • Compensation of mechanical tolerances. • Compensation of deflection due to load (tool, object and equipment on arm). Applications Any application where Absolute Accuracy is needed to facilitate: - Exchangeability of robots - Off-line programming with minimum touch-up. - On-line programming with accurate linear movement as well as accurate reorientation of tool - Re-use of programs between applications Controller algorithms Inherent mechanical tolerances and deflection due to load in the robot structure decrease the robot’s absolute accuracy. Practical compensation of such errors is a complex and highly non-linear problem. The ABB solution is to compensate positions internally in the controller, resulting in a defined and measurable robot TCP (Tool Center Point) accuracy. A generic robot control model is used for each robot family and robot individuals are described by a set of error parameters, generated during calibration at ABB Automation Technology Products, Robotics. Accuracy of each robot will be ascertained and verified through the “Birth Certificate” which statistically describes the robot accuracy in a large sample of robot positions.

Product Specification RobotWare Options for BaseWare OS 4.0

5

[544] Absolute Accuracy Performance Once the Absolute Accuracy parameter file is loaded and activated, the robot can be used. Absolute Accuracy is active in: - Motion function based on robtarget (MoveJ, MoveL, MoveC and ModPos) - Reorientation jogging - Linear jogging (no online compensation as the user defines the physical location, but absolute coordinates are determined for the active pose and shown in jogging window) - Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool) - Workobject definition Absolute Accuracy is inactive in: - Motion function based on a jointtarget (MoveAbsJ). Independent joint - Joint based jogging - External axes - Track motion - Any feature not listed in “Absolute Accuracy is active in” For joint based motions, switching to the jogging window and selecting a cartesian jog mode (Linear, Reorient) will show the correct absolute coordinates. Similarly creation of a robtarget at a point taught by joint based motion will be absolutely accurate. Requirements Each Absolute Accuracy robot is shipped with an error parameter file that is unique to that robot. This file must be loaded into the controller and subsequently activated in order to use Absolute Accuracy. Absolute Accuracy functionality may also be deactivated. Both actions require a cabinet restart. Supported robot types Please contact your local ABB office in order to get the latest list of supported robot types. RAPID instructions included in this option No specific RAPID instructions are included.

6

Product Specification RobotWare Options for BaseWare OS 4.0

[541] Load Identification and Collision Detection (LidCode)

[541] 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 (not 640) IRB 7600 and for external manipulators IRBP-L, IRBP-K, IRBP-R and IRBP-A. Load identification is not available for the hanging variants of IRB 1400 and IRB 2400 robots. LidCode contains two very useful features: Load Identification To manually calculate or measure the load parameters accurately can be very difficult and time consuming. Operating a robot with inaccurate load parameters can have a detrimental influence on cycle time and path accuracy. With LidCode, the robot can carry out accurate identification of the complete load data (mass, centre of gravity, and three inertia components). If applicable, tool load and payload are handled separately. The identification procedure consists of limited predefined movements of axes 3, 5 and 6 during approximately three minutes. The starting point of the identification motion pattern can be chosen by the user so that collisions are avoided. The accuracy achieved is normally better than 5%. Collision Detection Abnormal torque levels on any robot axis (not external axes) are detected and will cause the robot to stop quickly and thereafter back off to relieve forces between the robot and environment. Tuning is normally not required, but the sensitivity can be changed from Rapid or manually (the supervision can even be switched off completely). This may be necessary when strong process forces are acting on the robot. The sensitivity (with default tuning) is comparable to the mechanical alternative (mechanical clutch) and in most cases much better. In addition, LidCode has the advantages of no added stick-out and weight, no need for connection to the e-stop circuit, no wear, the automatic backing off after collision and, finally, the adjustable tuning. Two system outputs reflect the activation and the trig status of the function. RAPID instructions included in this option MotionSup ParIdRobValid

Changing the sensitivity of the collision detection or activating/deactivating the function. Checking that identification is available for a specific robot type.

Product Specification RobotWare Options for BaseWare OS 4.0

7

[541] Load Identification and Collision Detection (LidCode) ParIdPosValid LoadId MechUnitLoad

8

Checking that the current position is OK for identification. Performing identification. Definition of payload for external mechanical units.

Product Specification RobotWare Options for BaseWare OS 4.0

[542] ScreenViewer

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

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

View

File

| | | | | | | | |

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

| | | | | | | | | |

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

(Copy)

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

Valid

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

Product Specification RobotWare Options for BaseWare OS 4.0

9

[542] ScreenViewer A screen event can occur - When a new screen is displayed (to initialize the screen contents). - After a chosen interval (to refresh a screen). - When a menu choice or a function key is selected (to execute a specific action, or change the screen). - When a new value is entered in a field, or when a new field is selected (to execute some specific action). The commands that can be executed on screen events are - Reading/writing RAPID or I/O data. - Reading/writing fields contents. - Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the data read. - Comparing data read (=, ) and carrying out a command or not, depending on the comparison result. - Displaying a different screen. Capacities The user screens can be grouped in a screen package file under a specific name. Up to 8 packages can be loaded at the same time. A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen packages. - The screen package to be displayed is selected using the far right hand menu “View” (which shows a list of the screen packages installed). ScreenMaker ScreenMaker is a complete tool for creating and editing screens for the ScreenViewer on desktop computers running Windows 95/98 or Windows NT. See ScreenMaker Product Specification.

10

Product Specification RobotWare Options for BaseWare OS 4.0

[532] Multitasking

[532] Multitasking Up to 10 programs (tasks) can be executed in parallel with the normal robot program. - These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode. - They are programmed using standard RAPID instructions, except for motion instructions. - They can be programmed to carry out various activities in manual or automatic mode, and depending on whether or not the main process is running. - Communication between tasks is carried out via I/O or global data. - Priorities can be set between the processes. Examples of applications: - The robot is continuously monitoring certain signals even when the robot program has stopped, thus taking over the job traditionally allocated to a PLC. - An operator dialogue is required at the same time as the robot is doing, for example, welding. By putting this operator dialogue into a background task, the operator can specify input data for the next work cycle without having to stop the robot. - The robot is controlling a piece of external equipment in parallel with the normal program execution. Performance When the various processes are programmed in the correct way, no performance problems will normally occur: - When the priorities for the various processes are correctly set, the normal program execution of the robot will not be affected. - Because monitoring is implemented via interrupts (instead of checking conditions at regular intervals), processor time is required only when something actually happens. - All input and output signals are accessible for each process. Note that the response time of Multitasking does not match that of a PLC. Multitasking is primary intended for less demanding tasks. The normal response time is about 5 ms, but in the worst cases, e.g. when the processor is computing new movements, it can be up to 120 ms. 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.

Product Specification RobotWare Options for BaseWare OS 4.0

11

[531] Advanced Motion

[531] Advanced Motion Contains functions that offer the following possibilities: - Resetting the work area for an axis. - Independent movements. - Contour tracking. - Coordinated motion with external manipulators. Resetting the work area for an axis The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements. Examples of applications: - When polishing, a large work area is sometimes needed on the robot axis 4 or axis 6 in order to be able to carry out final polishing without stopping. Assume that the axis has rotated 3 turns, for example. It can now be reset using this function, without having to physically rotate it back again. Obviously this will reduce cycle times. - When arc welding, the work object is often fitted to a rotating external axis. If this axis is rotated more than one turn during welding, the cycle time can be reduced because it is not necessary to rotate the axis back between welding cycles. Coordinated motion with multi-axis manipulators Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires the Advanced Motion option. Note that simultaneous coordination with several single axis manipulators, e.g. track motion and workpiece manipulator, does not require Advanced Motion. Note! There is a built-in general method for defining the geometry for a manipulator comprising two rotating axes (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest local ABB office. Contour tracking Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion. Example of application: - A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted. 12

Product Specification RobotWare Options for BaseWare OS 4.0

[531] Advanced Motion Independent movements A linear or rotating axis can be run independently of the other axes in the robot system. The independent movement can be programmed as an absolute or relative position. A continuous movement with a specific speed can also be programmed. Examples of applications: - A robot is working with two different stations (external axes). First, a work object located at station 1 is welded. When this operation is completed, station 1 is moved to a position where it is easy to change the work object and at the same time the robot welds the work object at station 2. Station 1 is moved independently of the robot’s movement, which simplifies programming and reduces the cycle time. - The work object is located on an external axis that rotates continuously at a constant speed. In the mean time, the robot sprays plasma, for example, on the work object. When this is finished the work area is reset for the external axis in order to shorten the cycle time. Friction Compensation During low speed (10-100 mm/s) cutting of fine profiles, in particular small circles, a friction effect, typically in the form of approximately 0.5 mm “bumps”, can be noted. Advanced Motion offers a possibility of compensating for these frictional effects. Typically a 0.5 mm “bump” can be reduced to about 0.1 mm. This, however, requires careful tuning of the friction level (see User’s Guide for tuning procedure). Note that even with careful tuning, there is no guarantee that “perfect” paths can always be generated. For the IRB 6400 family of robots, no significant effects can be expected by applying Friction Compensation. RAPID instructions and functions included in this option IndReset IndAMove IndDMove IndRMove IndCMove IndInpos IndSpeed CorrCon CorrWrite CorrRead CorrDiscon CorrClear

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

Product Specification RobotWare Options for BaseWare OS 4.0

13

[530] Advanced Functions

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

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Product Specification RobotWare Options for BaseWare OS 4.0

[530] Advanced Functions Fixed position output The value of an output (digital, analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. The output will then change at the same place every time, irrespective of the robot’s speed. Consideration can also be given to time delays in the process equipment. By specifying this time delay, the output is set at the corresponding time before the robot reaches the specified position. The distance can also be specified as a certain time before the programmed position. This time (max. 500 ms) must be within the deceleration time when approaching that position. Examples of applications: - Handling press work, to provide a safe signalling system between the robot and the press, which will reduce cycle times. Just as the robot leaves the press, an output is set that starts the press. - Starting and finishing process equipment. When using this function, the start will always occur at the same position irrespective of the speed. For dispensing and sealing, see DispenseWare. Fixed position IO check The value of an input/output signal (digital, analog or group) can be checked at a certain distance before or after a programmed position. The signal will then be checked at the same place every time, irrespective of the robot's speed. The distance can also be specified as a certain time (max 500 ms) before the programmed position. The data being checked is compared with a certain programmed value and if the comparison is false, the robot will stop and an interrupt routine will be executed. In the interrupt routine appropriate error handling can be executed. Examples of applications: - A robot is used for extraction of parts from a die casting machine. Before entering the machine the robot can check, in the fly, if the gate is open. If not, the robot will stop and, in the interrupt routine, wait for the gate to open. Fixed position procedure call A procedure call can be carried out when the robot passes the middle of a corner zone. The position will remain the same, irrespective of the robot’s speed. Example of application: - In the press example above, it may be necessary to check a number of logical conditions before setting the output that starts the press. A procedure which takes care of the complete press start operation is called at a position just outside the press. Product Specification RobotWare Options for BaseWare OS 4.0

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[530] Advanced Functions World Zones A spherical, cylindrical or cubical volume can be defined within the working space. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”, both during program execution and when the robot is jogged into this area. The areas, which are defined in the world coordinate system, can be automatically activated at start-up or activated/deactivated from within the program. Examples of applications: - A volume is defining the home position of the robot. When the robot is started from a PLC, the PLC will check that the robot is inside the home volume, i.e. the corresponding output is set. - The volume is defining where peripheral equipment is located within the working space of the robot. This ensures that the robot cannot be moved into this volume. - A robot is working inside a box. By defining the outside of the box as a forbidden area, the robot cannot run into the walls of the box. - Handshaking between two robots both working in the same working space. When one of the robots enters the common working space, it sets an output and after that enters only when the corresponding output from the other robot is reset. Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one. The robot stores information about the original movement path which allows it to be resumed later. Examples of applications: - Cleaning the welding gun when a welding fault occurs. When a welding fault occurs, there is normally a jump to the program’s error handler. The welding movement in progress can be stored and the robot is ordered to the cleaning position so that the nozzle can be cleaned. The welding process can then be restarted, with the correct parameters, at the position where the welding fault occurred. This is all automatic, without any need to call the operator. (This requires options ArcWare or ArcWare Plus.) - Via an input, the robot can be ordered to interrupt program execution and go to a service position, for example. When program execution is later restarted (manually or automatically) the robot resumes the interrupted movement. Cross-connections with logical conditions Logical conditions for digital input and output signals can be defined in the robot’s system parameters using AND, OR and NOT. Functionality similar to that of a PLC can be obtained in this way.

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Product Specification RobotWare Options for BaseWare OS 4.0

[530] Advanced Functions Example: - Output 1 = Input 2 AND Output 5. - Input 3 = Output 7 OR NOT Output 8. Examples of applications: - Program execution to be interrupted when both inputs 3 and 4 become high. - A register is to be incremented when input 5 is set, but only when output 5=1 and input 3=0. Interrupts from analog input or output signals An interrupt can be generated if an analog input (or output) signal falls within or outside a specified interval. RAPID instructions and functions included in this option Open Close Write WriteBin WriteStrBin ReadNum ReadStr ReadBin Rewind WriteAnyBin ReadAnyBin ReadStrBin ClearIOBuff WZBoxDef WZCylDef WZLimSup WZSphDef WZDOSet WZDisable WZEnable WZFree StorePath RestoPath TriggC TriggL TriggJ TriggIO TriggEquip TriggCheckIO TriggInt MoveCSync MoveLSync

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

Product Specification RobotWare Options for BaseWare OS 4.0

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[530] Advanced Functions MoveJSync ISignalAI ISignalAO

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Position fix procedure call during joint movement Interrupts from analog input signal Interrupts from analog output signal

Product Specification RobotWare Options for BaseWare OS 4.0

[537] Developer’s Function

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

Data type for a byte data Set a specified bit in a byte Clear a specified bit in a byte Check if a specified bit in a byte is set Logical bitwise AND operation on byte Logical bitwise OR operation on byte Logical bitwise XOR operation on byte Logical bitwise NEGATION operation on byte Logical bitwise LEFT SHIFT operation on byte Logical bitwise RIGHT SHIFT operation on byte

Product Specification RobotWare Options for BaseWare OS 4.0

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

Define the search criteria

GetNextSym

Search next data and get its name as a string

GetDataVal

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

SetDataVal

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

RAPID Support Functions This package includes a number of miscellaneous instructions etc., which are used in application development. User defined data typesThis will make it possible to create your own data types, like a record definition

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AliasIO

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

ArgName

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

BookErrNo

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

TextTabGet

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

TextGet

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

TextTabInstall

Instruction used to install a text table in the system.

TextTabFreeToUse

Function to test whether the text table name (text resource string) is free to use.

IsSysId

Function used to test the system identity.

SetSysData

Instruction which will activates the specified system data (tool or workobject). With this instruction it is possible to change the current active tool or workobject. Product Specification RobotWare Options for BaseWare OS 4.0

[537] Developer’s Function IsStopStateEvent

Function which will return information about the movement of 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 at power on. The following instructions are included and are normally used in the power on event routine: PFIOResto

Restore the values of all digital output signals.

PFDOVal

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

PFGOVal

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

PFRestart

Check if path has been interrupted.

Trigg Functions TriggSpeed

Instruction to define conditions and actions for control of an analog output signal with an output value proportional to the actual TCP speed. Note that this instruction must be used in combination with a TriggL/C/J instruction (see [530] Advanced Functions).

StepBwdPath

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

TriggStopProc

Generation of restart data at program stop or emergency stop.

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

Datatype for variables referencing a directory Create a new directory Open a directory to read the underlaying files or subdirectories Close a directory Delete a directory Read next object in a directory, file or subdirectory Delete a file Check the type of a file

Product Specification RobotWare Options for BaseWare OS 4.0

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[537] Developer’s Function FileSize FSSize

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Get the size of a file Get the size of a file system

Product Specification RobotWare Options for BaseWare OS 4.0

[558] Discrete Application

[558] Discrete Application Discrete Applications Platform (DAP) is a software platform for time critical applications, where certain actions shall be performed at specific robot positions. Target users are advanced application software engineers and system integrators, e.g. for spot welding, drilling, measuring, quality control. The main advantages are achieved in the following areas: - Development time - Program execution time. - RAPID- program memory needed - Similar “look and feel” between applications - Tested kernel software Features • Specialized RAPID instructions and datatypes. • A single instruction for motion and process execution. • Combination of fine point positioning with execution of up to 4 parallel processes. • Specialized process for monitoring of external process devices, like spot welding controllers. • Supports encapsulation of the process and motion, in shell-routines provided to the end-user. • The Advanced Functions option is included in DAP. Application Creation of software for advanced applications with a discrete behaviour, such as spot welding, drilling, measuring, quality control. Performance C-code kernel and RAPID calls. The DAP platform is designed to have an internal kernel, administrating the fast and quality secured process sequence skeleton. The kernel calls RAPID routines, which are prepared by the application writer to fulfil the specific tasks. The application developer regulates the degree of flexibility of the end-user. Requirements There are no other requirements than S4CPlus cabinet and BaseWare. Rapid instructions included in this option See RAPID Discrete Application Platform User’s Guide.

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Product Specification RobotWare Options for BaseWare OS 4.0

[540] Conveyor Tracking

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

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

Product Specification RobotWare Options for BaseWare OS 4.0

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[533] Electronically Linked Motors

[533] Electronically Linked Motors This option is used to make master/slave configurations of motors, which are defined as external axes. The main application is to replace mechanical driving shafts of Gantry machines, but the option can be used to control any other set of motors as well. Features • Up to 4 master motors. • Up to 11 motors total (masters and followers). • Jogging and calibration routines. • Replacement of mechanical driving shafts. • Arm/Motor position available on the TPU. • Possibility to activate/deactivate link during process. • Automatic calibration at startup. Application Gantry machines: to replace mechanical driving shafts. Requirements There are no software or hardware requirements for this option. Performance - When jogging, the electronically linked motors will follow the master motor - Calibration – running follower motors independent of the master - is performed through a RAPID calibration program, to ensure high personnel safety - At startup, a routine will automatically set the master- and follower motors at the start position, through a safe maneuver RAPID instruction included in this option There are no RAPID instructions included in this option.

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Product Specification RobotWare Options for BaseWare OS 4.0

[547]Sensor Synchronization

[547] Sensor Synchronization Sensor Synchronization adjusts the robot speed to an external moving device (e.g. a press or conveyor) with the help of a sensor. This option simplifies programming and improves productivity of any loading /unloading application since it provides automatic sensor status check and speed adjustment. The robot TCP speed will be adjusted in correlation to the sensor output so that the robot will reach the programmed robtargets at the same time as the external device reaches their programmed positions. The synchronization is started/stopped with a new instruction, SyncToSensor, combined with movement instructions (fine points or corner zones). Note that hardware components for measuring the sensor output are needed for this function. The same hardware as for Conveyor Tracking is used: encoder and canbus boards. Please refer to the Product Specification for your robot. Features • Up to 4 sensors/robot. • “On-the-fly” activation. • Valid for any type of movement. • RAPID access to sensor and queue data. • Object queue: the same functionality as conveyor tracking. Applications Press synchronization “Side robot”or “Top_Robot “ (1 plane work robot NOFAC), paint application Performance The TCP will stay within ±50ms delay of the teached sensor position with linear sensor and constant sensor speed. Rapid instructions included in this option SyncToSensor WaitSensor DropSensor

Start/stop synchronization Connect to an object in the start window Disconnect from current object

Product Specification RobotWare Options for BaseWare OS 4.0

25

[539] Sensor Interface

[539] Sensor Interface The Sensor Interface option can be used to integrate sensor equipment for adaptive control, like path correction or process tuning. The option includes a driver for serial communication with the sensor system using a specific link protocol (RTP1) and a specific application protocol (LTAPP). The communication link makes it easy to exchange data between the robot controller and the sensor system, using predefined numbers for different data like x,y,z offset values, gap between sheets, time stamp etc. Features • Interrupt routines, based on sensor data changes. • Read/write sensor data from/to sensors using RAPID functions. • Store/retrieve sensor data as a block to/from a mass memory. • Seam tracking functionality, when combined with option Advanced Motion, based on using the contour tracking (path correction) functionality. Application In any application where it is wanted to read/control a sensor during execution, and to react on changes in certain data, like path offset or process supervisory data, thus making adaptive seam tracking and process control possible. Requirements External sensors communicating with the robot controller via serial links. RAPID instruction included in this option IVarValue ReadBlock ReadVar WriteBlock WriteVar

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Used to order and enable an interrupt when the value of a variable accessed via the serial sensor interface has been changed Used to read a block of data from a device connected to the serial sensor interface Used to read a variable from a device connected to the serial sensor interface Used to write a block of data to a device connected to the serial sensor interface Used to write a variable to a device connected to the serial sensor interface

Product Specification RobotWare Options for BaseWare OS 4.0

[561] Servo Tool Control

[561] Servo Tool Control The Servo Tool Control is a general and flexible software platform for controlling an integrated servo tool from S4CPlus. For additional features, like control of external processes, or control of several ServoGuns in parallel, please refer to the option SpotWare Servo. Target users are advanced system integrators who want to develop customer specific application software, such as spotwelding packages. As a “quick-start”, the option includes an example code package. This package can be used as a base for application development. Features • Position control (gap). • Force control. • Dynamic and kinematic model (tool configured as external axis). • Example code package. Application Spot Welding with Servo Guns: The option provides advanced control functionality for Servo Guns. Communication with Weld timers and other process control functionality needs to be implemented outside this option. For a total spot welding package, please refer to the option SpotWare Servo. Performance The tool is configured as an external axis, which ensures optimal performance, regarding path following and speed. (Dynamic and kinematic model.) The option Servo Tool Change can be added to the system in order to allow a switch between two or more servo tool, which will then utilize the same drive unit and measurement board. Requirements • Motion parameter file A specific servo tool parameter file has to be installed in the controller, for each servo tool. The parameter file is optimized for each system, concerning system behaviour and motion/process performance. • Drive Module & Measurement board See User’s Guide External Axes.

Product Specification RobotWare Options for BaseWare OS 4.0

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[561] Servo Tool Control Rapid instructions included in this option STClose STOpen STCalib STTune STTuneReset STIsClosed STIsOpen STCalcTorque STCalcForce

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Close a Servo Tool with a predefined force and thickness Open a Servo Tool Calibrate a Servo Tool Tune motion parameters for a Servo Tool Reset tuned motion parameters Test if a Servo Tool is closed Test if a Servo Tool is open Calculate the motor torque for a Servo Tool Calculate the programmable force for a Servo Tool

Product Specification RobotWare Options for BaseWare OS 4.0

[631] Servo Tool Change

[631] Servo Tool Change Servo Tool Change enables an on-line change of tools (external axes), for a certain drive- and measurement system. The control is switched between the axes by switching the motor cables from one servo motor to another. The switch is performed on-line, during production.

The main advantages are: - Flexibility in the production process One robot handles several tools - Minimized equipment A single drive-measurement system shared by many tools Features • On-line change of tools. • Up to 8 different tools. Application Servo gun changing; Robot held servo guns, designed for different reach and weld forces, equipped with different brands and sizes of servo motors, may be held and operated by a robot, switching from one servo gun to another. Servo Tool Change can be used as an independent option, or as an addition to the SpotWare Servo or Servo Toool Control options. Requirements Servo Tool Change requires a mechanical wrist interface, a Tool Changer. A MOC service parameter, Disconnect deactive = YES (Types: Measurement channel), must be set for each tool (external axis) used with this function. Performance When switching tools, the following steps are performed (switching from Axis 1 to Axis 2): - Axis 1 is deactivated using the RAPID instruction DeactUnit. - Axis 1 is disconnected from the motor cables. - Axis 2 is connected to the motor cables. - Axis 2 is activated using RAPID instruction ActUnit. After activation, Axis 2 is ready to run.

Product Specification RobotWare Options for BaseWare OS 4.0

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[631] Servo Tool Change The motor position at the moment of deactivation of one axis is saved and restored next time the axis is activated. Note: The motor position must not change more than half a motor revolution, when the axis is disconnected. In SpotWare Servo, there is a calibration routine, which handles larger position changes. RAPID instructions included in this option There are no specific RAPID instructions included in this option.

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Product Specification RobotWare Options for BaseWare OS 4.0

[535] RAP Communication

[535] RAP Communication This option is required for all communication with a superior computer, where none of the WebWare products are used. It includes the same functionality described for the option Factory Ware Interface. It also works for the WebWare products. There is no difference from the FactoryWare Interface (except that the price is higher). Note that both FactoryWare Interface and RAP Communication can be installed simultaneously.

Product Specification RobotWare Options for BaseWare OS 4.0

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[543] Ethernet Services

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

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Product Specification RobotWare Options for BaseWare OS 4.0

[534] FactoryWare Interface

[534] FactoryWare Interface This option enables the robot system to communicate with a PC. FactoryWare Interface serves as a run-time license for WebWare, i.e. the PC does not require any license protection when executing a WebWare based application. Factory Ware Interface includes the Robot Application Protocol (RAP). The Robot Application Protocol is used for computer communication. The following functions are supported: - Start and stop program execution - Transfer programs to/from the robot - Transfer system parameters to/from the robot - Transfer files to/from the robot - Read the robot status - Read and write data - Read and write output signals - Read input signals - Read error messages - Change robot mode - Read logs RAP communication is available both for serial links and network, as illustrated by the figure below. RAP RPC (Remote Procedure Call) TCP/IP Standard protocols SLIP

Ethernet

RS232/RS422 Examples of applications: - Production is controlled from a superior computer. Information about the robot status is displayed by the computer. Program execution is started and stopped from the computer, etc. - Transferring programs and parameters between the robot and a PC. When many different programs are used in the robot, the computer helps in keeping track of them and by doing back-ups. RAPID instruction included in this option SCWrite

Sends a message to the computer (using RAP)

Product Specification RobotWare Options for BaseWare OS 4.0

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[271] Interbus-S Configuration Tool

[271] Interbus Configuration Tool The Interbus Configuration Tool is used to configure the communication channels of the DSQC 512 board. (See ‘I/O Interfaces’, in the S4Cplus Product Specification.) The tool consists of standard PC software. The tool creates a bus configuration, which is used by the controller.

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Product Specification RobotWare Options for BaseWare OS 4.0

[270] Profibus DP Configuration Tool

[270] Profibus DP Configuration Tool The Profibus Configuration Tool is used to configure the master channel of the Profibus DP DSQC 510 board. (See ‘I/O Interfaces’, in the S4Cplus Product Specification.) The tool consists of standard PC software. The tool creates a bus configuration, which is used in the robot controller. Note: This tool is NOT needed for configuration and use of other channels than the master channel of the DSQC 510 board.

Product Specification RobotWare Options for BaseWare OS 4.0

35

[538] I/O Plus

[538] I/O Plus I/O Plus enables the S4Cplus 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 units, please contact the supplier. The communication between these units and S4Cplus has been verified (this does not, however, guarantee the internal functionality and quality of the units). Configuration data for the units is included. In I/O Plus there is also support for a so-called “Welder”. This is a project specific spot welding timer, and is not intended for general use. In addition to the above units, the I/O Plus “Generic Driver” also opens up the possibility to use other digital I/O units that conform with the DeviceNet specification. ABB does not assume any responsibility for the functionality or quality of such units. The user must provide the appropriate configuration data. I/O Plus also opens up the use of the second DeviceNet channel named CAN2, the configuration of the second channel is automatic if you have I/O Plus. I/O Plus also opens up the DeviceNet Slave functionality, which allow the S4Cplus controller to act as a slave unit towards another DeviceNet master, the configuration data for the slave unit is included.

36

Product Specification RobotWare Options for BaseWare OS 4.0

[551] ArcWare

3 ProcessWare [551] ArcWare ArcWare comprises a large number of dedicated arc welding functions, which make the robot well suited for arc welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. ArcWare functions A few examples of some useful functions are given below. Adaptation to different equipment The robot can handle different types of weld controllers and other welding equipment. Normally communication with the welding controller uses parallel signals but a serial interface is also available. Advanced process control Voltage, wire feed rate, and other process data can be controlled individually for each weld or part of a weld. The process data can be changed at the start and finish of a welding process in such a way that the best process result is achieved. Testing the program When testing a program, welding, weaving or weld guiding can all be blocked. This provides a way of testing the robot program without having the welding equipment connected. Automatic weld retry A function that can be configured to order one or more automatic weld retries after a process fault. Weaving The robot can implement a number of different weaving patterns up to 10 Hz depending on robot type. These can be used to fill the weld properly and in the best possible way. Weaving movement can also be ordered at the start of the weld in order to facilitate the initial striking of the arc.

Product Specification RobotWare Options for BaseWare OS 4.0

37

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

38

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

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

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

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

Analog outputs Voltage Wire feed Current Voltage adjustment Current adjustment

Description Weld voltage Velocity of wire feed Weld current Voltage synergic line amplification Current synergic line amplification

Product Specification RobotWare Options for BaseWare OS 4.0

[551] ArcWare Analog inputs (cont.)

Description (cont.)

Voltage

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

Current

RAPID instructions included in this option ArcL ArcC ArcKill ArcRefresh

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

Product Specification RobotWare Options for BaseWare OS 4.0

39

[552] ArcWare Plus

[552] 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 during welding. Path corrections during welding, i.e. when executing ArcL or ArcC instructions, can be made relative to the path using external sensors like Serial Weld Guide or Laser Track. Such corrections will take effect immediately, also during movement between two positions. The correction data are sent from the sensor system to the controller using a serial link and will automatically affect the path through built in functionality. Please note, that this option is compulsory for Serial Weld Guide systems (AWC) or Laser Track systems (M-Spot 90). - Contour tracking in normal movements (path corrections) Path corrections can also be activated when running normal movements like MoveL using specific RAPID path correction instructions. This functionality is also a part of option Advanced Motion, see this option for more information. - Adaptive process control for e.g. sensors like LaserTrak and Serial Weld Guide systems. The sensor can for instance provide the robot system with changes in the shape of the seam. These values can then be used to adapt the process parameters, like voltage or wire feed, to the current shape. (See option Sensor Interface for more information) RAPID instructions and functions included in this option CorrCon CorrWrite CorrRead CorrDiscon CorrClear SpcCon SpcWrite SpcDump SpcRead SpcDiscon IVarValue ReadBlock ReadVar WriteBlock WriteVar

40

Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators Activates statistical process supervision Provides the controller with values for statistical process supervision Dumps statistical process supervision data to a file or on a serial channel Reads statistical process supervision information Deactivates statistical process supervision Orders a variable interrupt Read a block of data from the sensor device Read a variable from the sensor device Write a block of data to the sensor device Write a variable to the sensor device

Product Specification RobotWare Options for BaseWare OS 4.0

[556] Arcitec

[556] Arcitec This option is intended to be used in combination with the Arcitec power sources. It shall only be ordered by the supplying unit of Arcitec. The package is a special software, used together with the ArcWare package, to be able to control not only the robot program but also the set up, configuration and programming of the power source. Thus the robot teach pendant will be used for programming and tuning both the robot and the power source. The package also includes a special aid for easy welding programming, i.e. the synergic function. This means that there is a pre-programmed relationsship between the wire feed rate and all other data components in the power source, making it easy to control the entire welding process, just by tuning the wire feed rate.

Product Specification RobotWare Options for BaseWare OS 4.0

41

[553] SpotWare

[553] SpotWare The Spotweld options are general and flexible software platforms for creation of customized and easy to use function packages for different types of spotweld systems and process equipments. The SpotWare option is used for sequential welding with one or several pneumatic gun equipments. If welding with several pneumatic guns at the same time is desired then the SpotWare Plus option has to be used instead. The SpotWare option provides dedicated spotweld instructions for fast and accurate positioning combined with gun manipulation, process start and supervision of the weld equipment. Communication with the welding equipment is normally carried out by means of digital inputs and outputs but a serial interface is also available for some type of weld timers. It should be noted that the SpotWare options are general and can be extensively customized. They have a default “ready to use” functionality directly after install but it is intended that some configuration data, RAPID data and RAPID routines has to be changed during the customizing. SpotWare features Some examples of useful functions are given below: - Fast and accurate positioning using the unique QuickMove and TrueMove concept. - Gun pre-closing. - Quick start after a weld. - Handling of an on/off gun with two strokes. - Dual/single gun. - Manual actions for welding and gun control. - Simulation possibilities for test purposes. - Reverse execution with gun control. - Spot counters. - User-defined supervision and error recovery. Weld error recovery with automatic rewelding. - User-defined continuous supervision of the weld equipment, such as weld current signal and water cooling start. Note: This feature requires the MultiTasking option. - Wide customizing possibilities.

42

Product Specification RobotWare Options for BaseWare OS 4.0

[553] SpotWare Principles of SpotWare The SpotWare functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous supervision and the spot welding will be handled in different independent processes. This means that if for instance the program execution and thus the robot movements is stopped, then the welding and supervision will continue until they come to a well defined process stop. For example, the welding process will carry on and finish the weld and open the gun, although the program has been stopped during the weld phase. For well defined points in the welding sequence and movements, calls to user routines offer adaptations to the plant environment. A number of predefined parameters are also available to shape the behaviour of the SpotWare instructions. Programming principles Both the robot movement and the control of the spot weld equipment are embedded in the basic spot weld instructions SpotL and SpotJ. The spot welding process is specified by: - Spotdata: spot weld process data - Gundata: spot weld equipment data - The system modules SWUSRC and SWUSRF: RAPID routines and global data for changing of process and test behaviour. - System parameters: the I/O Signal configuration. Spot welding instructions Instruction

Used to:

SpotL

Control the motion, gun closure/opening and the welding process. Move the TCP along a linear path and perform a spot welding at the end position.

SpotJ

Control the motion, gun closure/opening and the welding process. Move the TCP along a non-linear path and perform a spot welding at the end position.

Spot welding data Data type

Used to define:

spotdata

The spot weld process

gundata

The spot weld equipment

Product Specification RobotWare Options for BaseWare OS 4.0

43

[554] SpotWare Plus

[554] SpotWare Plus The SpotWare Plus package provides support for sequential welding with one or several pneumatic on/off gun equipments, as the SpotWare package, but also welding and full individual monitoring of up to four separate gun equipments at the same time. SpotWare Plus features The SpotWare Plus package contains the same features as SpotWare but with following feature in addition: - Possibility to weld with up to four guns at the same time. Principles of SpotWare Plus As in SpotWare the spotweld functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous supervision and each spotweld process will be handled in different independent program processes. This means that if for instance the program execution and thus the robot movements is stopped, then the weld processes and supervision will continue until they come to a well defined process stop. For example, the welding processes will carry on and finish the welds and open the guns, although the program has been stopped during the weld phase. For well defined points in the welding sequence, calls to user routines offer adaptations to the plant environment. A number of predefined parameters are also available to shape the behaviour of the SpotWare instruction. The opening and closing of the guns are always executed by RAPID routines. These gun routines may be changed from the simple on/off default functionality to a more complex gun control and they may contain additional gun supervision. SpotWarePlus is based on the DAP (Discrete Application Platform). Programming principles Both the robot movement and control of up to four spot weld processes are embedded in the basic spot weld instructions for multiple welding, SpotML and SpotMJ. Each spot welding process is specified by: - Spotmdata: spot weld process data - Gunmdata: spot weld equipment data - The system modules SWUSRF and SWUSRC: RAPID routines and global data for customizing purposes and data for changing of process and test behaviour. - System parameters: the I/O Signal configuration.

44

Product Specification RobotWare Options for BaseWare OS 4.0

[554] SpotWare Plus Spot welding instructions Instruction

Used to:

SpotML

Control the motion, gun closure/opening and 1 - 4 welding processes. Move the TCP along a linear path and perform spot welding with 1 - 4 gun equipments at the end position.

SpotMJ

Control the motion, gun closure/opening and 1 - 4 welding processes. Move the TCP along a non-linear path and perform spot welding with 1 - 4 gun equipments at the end position.

Spot welding data Data type

Used to define:

spotmdata

The spot weld process

gunmdata

The spot weld equipment

Product Specification RobotWare Options for BaseWare OS 4.0

45

[625] SpotWare Servo

[625] SpotWare Servo The Spotweld options are general and flexible software platforms for creation of customized and easy to use function packages for different types of spotweld systems and process equipments. The SpotWare Servo option is used for sequential welding with one or two servo gun equipments. If also welding with two servo guns at the same time is desired then the SpotWare Servo Plus option has to be used instead. The SpotWareServo option provides dedicated spotweld instructions for fast and accurate positioning combined with gun manipulation, process start and supervision of the different gun equipments. Communication with the welding equipment is carried out by means of digital inputs and outputs. It should be noted that the SpotWare options are general and can be extensively customized. They have a default “ready to use” functionality directly after install but it is intended that some configuration data, RAPID data and RAPID routines has to be changed during the customizing. SpotWare Servo features The SpotWare Servo package contains the following features: - Fast and accurate positioning using the unique QuickMove and TrueMove concept. - Gun pre-closing, i.e having the gun closing synchronized with weld position. - Gun equalizing, i.e. having the gun “floating” around the weld position. - Constant tip force during welding. - Manual actions for welding and gun control. - Several simulation possibilities for test purposes. - Reverse execution with gun control. - Weld error recovery with automatic rewelding. - User-defined supervision and error recovery. - User-defined autonomous supervision, such as weld current signal and water cooling start. - Wide customizing possibilities. - Default “ready to use” functionality directly after install. - Detecting of missing or improper plates. - Gun calibration functions. - Spot counters and tip wear data for each used gun.

46

Product Specification RobotWare Options for BaseWare OS 4.0

[625] SpotWare Servo - Fast switch between two servo guns with a tool changer. Note: This feature requires the Servo Tool Change option. Principles of SpotWare Servo The SpotWare functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous supervision and the spotwelding will be handled in different independent processes. This means that if for instance the program execution and thus the robot movements is stopped, then the welding and supervision will continue until they come to a well defined process stop. For example, the welding process will carry on and finish the weld and open the gun, although the program has been stopped during the weld phase. For well defined points in the welding sequence and movements, calls to user routines offer adaptations to the plant environment. A number of predefined parameters are also available to shape the behaviour of the SpotWare instructions. Programming principles Both the robot movement and the control of the spot weld equipment are embedded in the basic spot weld instructions SpotL and SpotJ. The spot welding process is specified by: - Spotdata: spot weld process data - Gundata: spot weld equipment data - The system modules SWDEFINE and SWDEFUSR: RAPID routines and global data for customizing purposes e.g. adaptations for a specific process equipment. - The system module SWUSER: RAPID routines and global data for changing of process and test behaviour. - System parameters: the I/O Signal configuration and the Manipulator configuration.

Product Specification RobotWare Options for BaseWare OS 4.0

47

[625] SpotWare Servo Spot welding instructions Instruction

Used to:

SpotL

Control the motion, gun closure/opening and the welding process. Move the TCP along a linear path and perform a spot welding at the end position.

SpotJ

Control the motion, gun closure/opening and the welding process. Move the TCP along a non-linear path and perform a spot welding at the end position.

SetForce

Close the gun a predefined time then open the gun.

CalibL

Calibrate the gun during linear movement to the programmed position.

CalibJ

Calibrate the gun during non-linear movement to the programmed position.

Calibrate

Calibrate the gun in current position without movement.

STTune

Tune motion parameters for the servo gun.

STTuneReset

Reset tuned motion parameters for the servo gun.

Spot welding data

48

Data type

Used to define:

spotdata

The spot weld process

gundata

The spot weld equipment

forcedata

The SetForce process

simdata

Simulation modes

Product Specification RobotWare Options for BaseWare OS 4.0

[626] SpotWare Servo Plus

[626] SpotWare Servo Plus The SpotWare Servo Plus package provides support for sequential welding with one or several servo gun equipments, as the SpotWare Servo package, but also welding with two servo guns at the same time. SpotWare Servo Plus features The SpotWare Servo Plus package contains the same features as SpotWareServo but with following feature in addition: - Possibility to weld with two servo guns at the same time. Principles of SpotWare Servo Plus As in SpotWare Servo the SpotWare functions will be controlled by separate internal program processes, which will run in parallel. For instance the robot movements, the continuous supervision and the spotwelding will be handled in different independent processes. This means that if for instance the program execution and thus the robot movements is stopped, then the weld processes and supervision will continue until they come to a well defined process stop. For example, the welding processes will carry on and finish the weld and open the guns, although the program has been stopped during the weld phase. Programming principles Both the robot movement and the control of the spot weld equipments are embedded in the basic spot weld instructions. SpotL and SpotJ are used for sequential welding. With SpotML or SpotMJ it is possible to weld with several guns simultaneously. Each spot welding process is specified by: - Spotdata: spot weld process data - Gundata: spot weld equipment data - The system modules SWDEFINE and SWDEFUSR: RAPID routines and global data for customizing purposes e.g. adaptations for a specific process equipment. - The system module SWUSER: RAPID routines and global data for changing of process and test behaviour. - System parameters: the I/O Signal configuration and the Manipulator configuration. Spot welding instructions The SpotWare Servo Plus package contains the same instructions as SpotWareServo plus following instructions in addition:

Product Specification RobotWare Options for BaseWare OS 4.0

49

[626] SpotWare Servo Plus

50

Instruction

Used to:

SpotML

Control the motion, gun closure/opening and 1 - 2 welding processes. Move the TCP along a linear path and perform spot welding with 1 - 2 gun equipments at the end position.

SpotMJ

Control the motion, gun closure/opening and 1 - 2 welding processes. Move the TCP along a non-linear path and perform spot welding with 1 - 2 gun equipments at the end position.

Product Specification RobotWare Options for BaseWare OS 4.0

[569] DispenseWare

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

Product Specification RobotWare Options for BaseWare OS 4.0

51

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

Used to:

DispL

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

DispC

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

Dispensing data

52

Data type

Used to define:

beaddata

Dispensing data for the different beads.

equipdata

Dispensing data for the equipment in use.

Product Specification RobotWare Options for BaseWare OS 4.0

[571] PalletWare

[571] PalletWare General PalletWare is a ready-to-use software package for the S4Cplus controller, focused on palletizing. PalletWare imports data created with PalletWizard, the included off-line PC-tool, to execute the defined palletizing cycles. PalletWare has a predefined interface for connecting PLC (Programmable Logic Controller), which is the most common way to control external equipment such as infeeders, outfeeders and sensor equipment. The standard package includes software components such as priority and scheduling routines that are ready to use. The package also includes components that can be customized, e.g. grip tool control routines. PalletWare supports system integrators who want to customize the system, by presenting a standardized interface. What is included Included in the PalletWare package is software components to control robot motion, and to communicate with the user and external equipment. In order to minimize commissioning time, PalletWare is equipped with a standardized set of modules, referred to as the Standard Package Add-On. Advanced users can replace these modules with their own if special customizing is needed. PalletWare is also delivered with template user routines that handles the most common solutions. PalletWare offers a standardized interface where to connect all external equipment such as infeeders, PLC, signal board, grip tool, sensor equipment etc. The package includes a set of predefined signals connected to a simulated board. The integrator has to implement the signal board and connect the signals. The configuration file for the signals has also to be modified depending on what type of board is used. Because of the large amount of signals, it is recommended to use a field bus such as for example Profibus. PalletWare features PalletWare offers for example following functionality: - Multiplacing - Parallel processing, up to 5 stations simultaneously - Multistationary production - User dialogue interface with Screen Viewer - On-line tuning of geometrical data - Safety functionality - Prepared PLC interface - Prepared MMI interface

Product Specification RobotWare Options for BaseWare OS 4.0

53

[571] PalletWare - Tool control - Standardized error handling - Predefined user routines Programming principles PalletWare is added to the BaseWare system. PalletWare consists of predefined motion principles and communication routines for communicating with external equipment. It is not necessarily needed to implement any RAPID code. However, the system supports integrators for customizing by standardized functions and instructions. Customizing PalletWare PalletWare can be up-and-running without any need for implementing RAPID code, but it must be adapted to the current robot cell and its physical lay-out. For instance, there are a number of steps which are compulsory, e.g: - Connect external equipment such as infeeders, tool, PLC etc., via the predefined interface. - Connect safety equipment such as emergency stop, safety fences etc. - Define tooldata if the tool does not match the templates - Check the set-up in the configuration module PAL_CFG. - Define/teach work objects to the stations - Define/teach robtarget with tool in zero orientation - Create and load pallet cycles with PalletWizard. In addition to this, PalletWare offers a great deal of customizing possibilities for advanced users, e.g. - Using tools with suction cups or mechanical gripper - Sliding uppermost layer to gain pallet height - Controlling orientation on infeeder - Add or skip safety height movements between stations - Set priority when working with several pallet cycles in parallel. - Etc. Pallet Wizard Pallet Wizard is a complete and easy to use stand alone tool running on a PC under Windows 95/98 or Windows NT, for off line programming of palletizing or depalletizing processes. It is delivered as a part of the PalletWare option package. In PalletWizard the complete cell with its different components like the products, the tools, the in/out feeders and pallet stations as well as the pallet cycles with the layers and the pattern descriptions can be defined. 54

Product Specification RobotWare Options for BaseWare OS 4.0

[571] PalletWare PalletWizard offers for example the following features: - Detailed On-line help - Wizards for defining the products, tools, cell definition, station configurations, pallet composition and the pallet cycles - Automatic pick- and place definition - Automatic calculating of grip zones to be used for the tool - Software based collision detection - Library of predefined patterns Several different pallet cycles can be combined into a production cycle and saved into a file, which can be downloaded to the robot. At the robot the operator can then select what specific pallet cycle to run and on which infeeder and pallet station.

Product Specification RobotWare Options for BaseWare OS 4.0

55

Index INDEX

4 Index A AbsAcc 5 Absolute Accuracy 5 Advanced functions 14 arc welding 37, 40 Arcitec 41 ArcWare 37 ArcWare Plus 40 B BaseWare 5 BaseWare Options 3 BaseWare OS 3 C Collision Detection 7 communication robot and PC 33 continuous movement 13 Contour tracking 12 Conveyor Tracking 23, 27, 29 coordinated motion 12 cross-connection locigal conditions 16

output 15 procedure call 15 Friction Compensation 13 FTP 32 I I/O Plus 36 independent movement 13 input or output signals interrupts 17 Interbus Configuration Tool 34 interrupt routine movement 16 interrupts from analog input or output signals 17 L Load Identification 7 logical conditions cross connections 16 N NFS 32 O output in fixed position 15 P

D data read and write 14, 33 transfer 14 Discrete Applications Platform 22 DispenseWare 51 E electronically linked motors 24 error handler movement 16 Ethernet Services 32 F file read and write 14, 33 fixed position

PalletWare 53 parallel processing 11 PLC functionality 16 printout 14 ProcessWare 3, 37 Profibus Configuration Tool 35 Profibus DP 35 program back-up 33 transfer 33 R RAP Communication 31 read data 14 file 14

Product Specification RobotWare Options for BaseWare OS 4.0

57

Index

Reset the work area 12 S Sensor Interface 26 Sensor Synchronization 25 serial channel 14 Servo Tool Change 29 Servo Tool Control 27 SpotWare Servo 46 SpotWare Servo Plus 49 T transfer data 14, 33 file 33 program 33 W World Zones 16 write data 14 file 14

58

Product Specification RobotWare Options for BaseWare OS 4.0

Installation Manual, IRB 6600/6650, M2000A 3HAC 16245-1 Revision A

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

©Copyright 2002 ABB All rights reserved. ABB Automation Technology Products AB Robotics SE-721 68 Västerås Sweden

Table of Contents

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Chapter 1: Safety, service

9

1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Section 1.1: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.1.1 Safety, service - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Section 1.2: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 1.2.6 Risks associated with live electric parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Section 1.3: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.3.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 1.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 1.3.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 1.3.5 Risk of disabling function "Reduced speed 250 mm/s". . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 1.3.7 Work inside the manipulator’s working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Chapter 2: Reference information

17

2.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Section 2.1: Reference information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.1.1 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.1.2 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.1.3 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 2.1.4 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 2.1.5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 2.1.6 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 2.1.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Chapter 3: Unpacking

27

3.0.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55 . . . . . . . . . . . . . . . . . . . . . . .30 3.0.3 Working range, IRB 6600 - 175/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 3.0.4 Working range, IRB 6650 - 125/3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 3.0.5 Working range, IRB 6650 - 200/2.75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.0.6 Risk of tipping/Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Chapter 4: On-site Installation

35

Section 4.1: On-site installation, manipulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

4.1.1 Lifting manipulator with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 4.1.2 Lifting manipulator with roundslings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 4.1.3 Lifting manipulator with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 4.1.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 4.1.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 4.1.6 Securing the base plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 4.1.7 Orienting and securing the manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 4.1.8 Fitting equipment on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 4.1.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

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Section 4.2: Restricting the working range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 4.2.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.2.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4.2.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 4.2.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Section 4.3: On-site installation, controller cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.3.1 Lifting the controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.3.2 Required installation space, control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Chapter 5: Electrical connections

75

Section 5.1: Signal/Power cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5.1.1 Connecting the manipulator to the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . 79 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A . . . . . . . . . . . . . . . . . . . . . 80 Section 5.2: Signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5.2.1 Signal Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.2.2 Selecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.2.3 Interference elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 5.2.4 Connection types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 5.2.5 Connections to screw terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.2.6 Connections to connectors (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Section 5.3: Customer connections on manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.3.1 Signal connections, SpotWelding Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 5.3.2 Signal connections, Material Handling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Section 5.4: Customer connections on controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.4.1 The MOTORS ON/MOTORS OFF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 5.4.2 External customer connections on panel X1 - X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 5.4.3 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Section 5.5: Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.5.1 External 24V supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 5.5.2 24V I/O supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 5.5.3 115/230 VAC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Section 5.6: Buses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.6.1 Connection of the CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 5.6.2 Interbus-S, slave DSQC 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 5.6.3 Profibus-DP, slave DSQC 352. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Section 5.7: I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5.7.1 Distributed I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 5.7.2 Distributed I/O, digital sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 5.7.3 Distributed I/O, digital I/O DSQC 328 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5.7.4 AD Combi I/O, DSQC 327 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5.7.5 Analog I/O, DSQC 355 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 5.7.6 Encoder interface unit, DSQC 354 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Section 5.8: Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5.8.1 Allen-Bradley, general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 5.8.2 RIO, remote I/O for Allen-Bradley PLC DSQC 350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 5.8.3 Communication, serial links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.8.4 Communication, Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 5.8.5 External operator’s panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Chapter 6: Start-up

139

6.0.1 Inspection before start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 6.0.2 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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Chapter 7: Installation of controller software

141

7.0.1 Loading system software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 7.0.2 RobotWare CD-ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 7.0.3 Installing new Robot Controller Software with RobInstall . . . . . . . . . . . . . . . . . . . . . . . . . .144 7.0.4 Create a new Robot Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 7.0.5 Update the Robot Controller image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 7.0.6 Transfer Robot Controller System using Ethernet connection. . . . . . . . . . . . . . . . . . . . . . . .151 7.0.7 Transfer Robot Controller System using floppy disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 7.0.8 RobInstall preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156 Chapter 8: Robot controller

157

8.0.1 BootImage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 8.0.2 Start window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158 8.0.3 Reboot Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 8.0.4 Boot Disk Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 8.0.5 LAN Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 8.0.6 Service Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 8.0.7 System selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 8.0.8 How to perform a Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 8.0.9 How to Start in Query Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 Chapter 9: System directory structure

169

9.0.1 Media pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 9.0.2 System pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 9.0.3 File structure in the robot controller mass storage memory. . . . . . . . . . . . . . . . . . . . . . . . . .171 9.0.4 Preparation of S4Cplus software to be installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 9.0.5 Handling mass memory storage capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 Chapter 10: Calibration

175

Section 10.1: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

10.1.1 Types of calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 10.1.2 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176 10.1.3 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 10.1.4 Calibration pendulum kit, contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 Section 10.2: Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

10.2.1 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 10.2.2 Updating the revolution counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 10.2.3 Calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 10.2.4 Initialization of calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 Section 10.3: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

10.3.1 Calibration sensor mounting positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 10.3.2 Calibration scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 10.3.3 Calibration, all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 10.3.4 Calibrating axes 3-4, IRB 7600/2.3/500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 Section 10.4: After calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

10.4.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 Section 10.5: Alternative calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

10.5.1 Alternative calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 10.5.2 Alternative calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 10.5.3 New calibration position, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 10.5.4 New calibration offset, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202 10.5.5 Retrieving offset values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

3HAC 16245-1

iii

Table of Contents

Chapter 11: Decommissioning

205

11.0.1 Balancing device, IRB 7600 and IRB 6600/6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

iv

3HAC 16245-1

0.0.1 Overview

0.0.1 Overview

About This Manual

This information product is a manual containing instructions for installing the complete robot system, mechanically as well as electrically.

Usage

This manual should be used during installation, from lifting the manipulator to its work site thru installing application software in the robot controller, making the robot ready for operation.

Who Should Read This Manual?

This manual is intended for:

Prerequisites

The reader should...

•

•

Organization of Chapters

installation personnel on the installation site.

have the required knowledge of mechanical as well as electrical installation work.

The information product is organized in the following chapters: Chapter

Contents

1

Safety, Service

2

Reference Information

3

Unpacking

4

On-site Installation

5

Electrical connections

6

Start-up

7

Installation of controller software

8

Robot controller

9

System directory structure

10

Calibration

11

Decommissioning

References

3HAC 16245-1

Reference

Document Id

Circuit Diagram, manipulator

3HAC 13347-1

Circuit Diagram, controller

3HAC 14189-2

A

5

0.0.1 Overview

Revisions Revision

Description

-

First edition

A

6

•

Various corrections in text and in figures due to reconstructions, new options, etc.

•

Manual completed with references to pagenumbers and numbering of sections (manipulator sections).

•

Manual completed with version IRB 6650.

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3HAC 16245-1

0.0.2 Product Documentation

0.0.2 Product Documentation

General

The complete product documentation kit for the robot, including controller, manipulator and any hardware option, consists of the manuals listed below:

Installation and Commissioning Manual

The Installation and Commissioning Manual contains the following information:

Repair Manual

Maintenance Manual

•

Safety, Service

•

Reference Information

•

Unpacking

•

On-site Installation

•

Electrical connections

•

Start-up

•

Installation of controller software

•

System directory structure

•

Calibration

•

If there is any, model specific information

The Repair Manual contains the following information: •

Safety, Service

•

Reference Information

•

Remove/Refitting instructions for all manipulator details considered spare parts

•

Remove/Refitting instructions for all controller cabinet details considered spare parts

•

If there is any, model specific information

The Maintenance Manual contains the following information: •

Safety, Service

•

Reference Information

•

Maintenance schedules

•

Instructions for all maintenance activities specified in the maintenance schedule, for example cleaning, lubrication, inspection etc.

•

If there is any, model specific information

The information is generally divided into separate chapters for the manipulator and the controller, respectively.

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation. A complete listing of all available software manuals is available from ABB Robotics.

3HAC 16245-1

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7

0.0.2 Product Documentation

Hardware option manual

Each hardware option is supplied with its own documentation. Each document set contains the types of information specified above: •

Installation information

•

Repair information

•

Maintenance information

In addition, spare part information is supplied for the complete option.

8

A

3HAC 16245-1

1 Safety, service 1.0.1 Introduction

Chapter 1: Safety, service 1.0.1 Introduction

Definitions

This chapter details safety information for service personnel i.e. personnel performing installation, repair and maintenance work.

Sections

The chapter "Safety, service" is divided into the following sections: 1. General information contains lists of: • Safety, service -general • Limitation of liability • Referenced documents

2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split into different categories: • Safety risks related to gripper/end effector • Safety risks related to tools/workpieces • Safety risks related to pneumatic/hydraulic systems • Safety risks during operational disturbances • Safety risks during installation and service • Risks associated with live electric parts

3. Safety actions details actions which may be taken to remedy or avoid dangers. • Safety fence dimensions • Fire extinguishing • Emergency release of the manipulator´s arm • Brake testing • Risk of disabling function "Reduced speed 250 mm/s" • Safe use of the Teach Pendant Unit enabling device • Work inside the manipulator´s working range

3HAC 16245-1

A

9

1 Safety, service 1.1.1 Safety, service - General

Section 1.1: General information 1.1.1 Safety, service - General

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User’s Guide and Product Manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.

1.1.2 Limitation of Liability

General

Any information given in this information product regarding safety, must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.

1.1.3 Related information

General

The list below specifies documents which contain useful information:

Documents

10

Type of information

Detailed in document

Installation of safety devices

Installation and Commissioning Manual

Changing robot modes

User’s Guide

Start-up

Restricting the working space

Installation and Commissioning Manual

On-site installation Manipulator

A

Section

3HAC 16245-1

1 Safety, service 1.2.1 Safety risks related to gripper

Section 1.2: Safety risks 1.2.1 Safety risks related to gripper Ensure that a gripper is prevented from dropping a workpiece, if such is used.

1.2.2 Safety risks related to tools/workpieces

Safe handling

It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

1.2.3 Safety risks related to pneumatic/hydraulic systems

General

Residual energy

Safe design

Special safety regulations apply to pneumatic and hydraulic systems.

•

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

•

The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

•

Gravity may cause any parts or objects held by these systems to drop.

•

Dump valves should be used in case of emergency.

•

Shot bolts should be used to prevent tools, etc., from falling due to gravity.

1.2.4 Safety risks during operational disturbances

General

Qualified personnel

Extraordinary risks

3HAC 16245-1

•

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

•

All work must be carried out professionally and in accordance with the applicable safety regulations.

•

Care must be taken at all times.

•

Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

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

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11

1 Safety, service 1.2.5 Safety risks during installation and service

1.2.5 Safety risks during installation and service

General risks during installation and service

Nation/region specific regulations

Non-voltage related risks

To be observed by the supplier of the complete system

•

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

•

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

•

Those in charge of operations must make sure that safety instructions are available for the installation in question.

•

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

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

•

Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

•

Turntables or the like should be used to keep the operator out of the robot's working space.

•

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

•

Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled.

•

When dismantling/assembling mechanical units, watch out for falling objects.

•

Be aware of stored heat energy in the controller.

•

Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

•

The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

•

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

1.2.6 Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, controller

12

•

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

•

The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

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

Be aware of stored electrical energy (DC link) in the controller.

A

3HAC 16245-1

1 Safety, service 1.2.6 Risks associated with live electric parts

•

Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.

•

The mains supply/mains switch

•

The power unit

•

The power supply unit for the computer system (230 VAC)

•

The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

•

The drive unit (700 VDC)

•

The service outlets (115/230 VAC)

•

The power supply unit for tools, or special power supply units for the machining process

•

The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.

•

Additional connections

Voltage related risks, manipulator

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

Voltage related risks, tools, material handling devices, etc

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

3HAC 16245-1

•

The power supply for the motors (up to 800 VDC)

•

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

A

13

1 Safety, service 1.3.1 Safety fence dimensions

Section 1.3: Safety actions 1.3.1 Safety fence dimensions

General

Fit a safety fence or enclosure around the robot to ensure a safe robot installation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.

1.3.2 Fire extinguishing Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipulator or controller)!

1.3.3 Emergency release of the manipulator’s arm

Description

In an emergency situation, any of the manipulator’s axes may be released manually by pushing the brake release buttons on the manipulator or on an optional external brake release unit. How to release the brakes is detailed in section "Manually releasing the brakes". The manipulator arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, which may further increase any injury!

1.3.4 Brake testing

When to test

During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.

How to test

The function of each axis’ motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate.

14

A

3HAC 16245-1

1 Safety, service 1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

1.3.5 Risk of disabling function "Reduced speed 250 mm/s" Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

1.3.6 Safe use of the Teach Pendant Unit The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: The enabling device must never be rendered inoperative in any way. During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. The programmer must always bring the Teach Pendant Unit with him/her, when entering the robot’s working space. This is to prevent anyone else taking control over the robot without the programmer knowing.

1.3.7 Work inside the manipulator’s working range If work must be carried out within the robot’s work envelope, the following points must be observed: - The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. - The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% ”full speed”may only be used by trained personnel who are aware of the risks that this entails. - Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. - Test the motor brake on each axis, according to section Brake testing on page 14.

3HAC 16245-1

A

15

1 Safety, service 1.3.7 Work inside the manipulator’s working range

16

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3HAC 16245-1

2 Reference information 2.0.1 Introduction

Chapter 2: Reference information 2.0.1 Introduction

General

3HAC 16245-1

This chapter presents generic pieces of information, complementing the more specific information in the following chapters.

A

17

2 Reference information 2.1.1 Applicable Safety Standards

Section 2.1: Reference information 2.1.1 Applicable Safety Standards

Standards, general

Standards, robot cell

18

The robot is designed in accordance with the requirements of: •

EN 775 - Robot safety.

•

EN 292-1 - Basic terminology.

•

EN 292-2 - Technical principles.

•

EN 418 - Emergency stop.

•

EN 563 - Temperatures of surfaces.

•

EN 954-1 - Safety related parts of control systems.

•

EN 60204-1 - Electrical equipment of machines.

•

EN 1050 - Principles for risk assessment.

•

ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.

•

DIN 19258 - Interbus-S, International Standard

The following standards are applicable when the robot is part of a robot cell: •

EN 953 - Fixed and moveable guards

•

EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.

•

EN 349 - Minimum gaps to avoid crushing of parts of the human body.

•

EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.

•

EN 1088 - Interlocking devices

•

EN 999 - The positioning of protective equipment in respect of approach speeds of the human body.

•

ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing systems.

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3HAC 16245-1

2 Reference information 2.1.2 Screw joints

2.1.2 Screw joints

General

This section details how to tighten the various types of screw joints on the manipulator as well as the controller. The instructions and torque values are valid for screw joints comprising metallic materials and do not apply to soft or brittle materials. Any instructions given in the repair, maintenance or installation procedure description override any value or procedure given here, i.e. these instruction are only valid for standard type screw joints.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB in certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue. Whenever used, this is specified in the instructions and in such cases no other type of replacement screw is allowed. Using other types of screw will void any warranty and may potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 (or another lubricant) should only be used when specified in the repair, maintenance or installation procedure descriptions. In such cases, proceed as follows: 1. Lubricate the thread of the screw. 2. Lubricate between the plain washer and screw head. 3. Tighten to the torque specified in section "Tightening torque" below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

3HAC 16245-1

Lubricant

Art. no.

Molycote 1000 (molybdenum disulphide grease)

1171 2016-618

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19

2 Reference information 2.1.2 Screw joints

Tightening torque

Screws with slotted or cross recess head

Below are tables specifying the torque values for different screw joint types:

Dimension

Tightening torque (Nm) Class 4.8 "dry"

M2.5

0.25

M3

0.5

M4

1.2

M5

2.5

M6

5.0

Screws with hexagon socket head, “dry”

Screws with hexagon socket head, lubricated

20

Dimension

Tightening torque (Nm) Class 8.8 "dry"

Tightening Tightening torque (Nm) torque (Nm) Class 10.9 "dry" Class 12.9 "dry"

M5

6

-

-

M6

10

-

-

M8

24

34

40

M10

47

67

80

M12

82

115

140

M16

200

290

340

Dimension

Tightening torque (Nm) Class 10.9

Tightening torque (Nm) Class 12.9

M8

28

34

M10

55

66

M12

96

115

M16

235

280

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3HAC 16245-1

2 Reference information 2.1.3 Weight specifications

2.1.3 Weight specifications

Definition

In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg to avoid inflicting injury. A wide range of lifting tools and devices is available for each manipulator model.

Example

Below is an example of how a weight specification is presented: The motor weighs 65 kg! All lifting equipment used must be dimensioned accordingly!

3HAC 16245-1

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21

2 Reference information 2.1.4 Standard toolkit

2.1.4 Standard toolkit

General

All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools required are listed directly in the instructions while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below. In this way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.

Contents, standard toolkit, 3HAC 15571-1

22

Qty

Tool

Rem.

1

Ring-open-end spanner 8-19mm

1

Socket head cap 5-17mm

1

Torx socket no:20-60

1

Box spanner set

1

Torque wrench 10-100Nm

1

Torque wrench 75-400Nm

1

Ratchet head for torque wrench 1/2

2

Hexagon-headed screw M10x100

1

Socket head cap no:14, socket 40mm bit L 100mm

1

Socket head cap no:14, socket 40mm bit L 20mm

1

Socket head cap no:6, socket 40mm bit L 145mm

A

To be shorted to 12mm

3HAC 16245-1

2 Reference information 2.1.5 Special tools

2.1.5 Special tools

General

All service (repairs, maintenance and installation) instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 22, and of special tools, listed directly in the instructions and also gathered in the table below.

Special tools, IRB 6600/6650/7600

The table below is an overview of all the special tools required when performing service activities on the IRB 6600/6650/7600. The tools are gathered in two kits: Basic Toolkit (3HAC 15571-3) and Extended Toolkit (3HAC 15571-2). The special tools are also listed directly in the current instructions.

3HAC 16245-1

Description

IRB 66X0/Qty IRB 7600/Qty Art. no.

Angel bracket

a

a

68080011-LP

Bolts (M16 x 60) for Mech stop ax 3 2

-

3HAB 3409-86

Bolts (M16 x 80) for Mech stop ax 3 -

2

3HAB 3409-89

Cal. tool

a

a

68080011-GM

Calibration bracket

a

-

3HAC 13908-9

Calibration tool ax1

a

a

3HAC 13908-4

CalPen (Calibration Pendulum)

1

1

3HAC 15716-1

Extension 300mm for bits 1/2"

1

1

3HAC 12342-1

Fixture lower arm

1

-

3HAC 13659-1

Fixture lower arm

-

1

3HAC 13660-1

Gearbox crank

1

-

3HAC 16488-1

Guide pins M12 x 150

2

-

3HAC 13056-2

Guide pins M12 x 200

2

-

3HAC 13056-3

Guide pins M12 x 250

1

-

3HAC 13056-4

Guide pins M8 x 100

2

-

3HAC 15520-1

Guide pins M8 x 150

2

-

3HAC 15520-2

Guide pins sealing

-

b

3HAC 14445-1

Guide pins sealing

b

-

3HAC 14446-1

Guide pins M10 x 100

2

2

3HAC 15521-1

Guide pins M10 x 150

2

2

3HAC 15521-2

Guide pins M16 x 150

-

2

3HAC 13120-2

Guide pins M16 x 200

-

2

3HAC 13120-3

Guide pins M16 x 250

-

1

3HAC 13120-4

Guide pins M16 x 300

2

2

3HAC 13120-5

Guide pins sealing ax 2, 3, 100mm

1

-

3HAC 14628-2

Guide pins sealing ax 2, 3, 80mm

1

-

3HAC 14628-1

Guide pins sealing ax 2, 3, 100mm

-

1

3HAC 14627-3

Guide pins sealing ax 2, 3, 80mm

-

1

3HAC 14627-2

Hydraulic cylinder

1

1

3HAC 11731-1

Hydraulic pump 80Mpa

1

1

3HAC 13086-1

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23

2 Reference information 2.1.5 Special tools

Description

IRB 66X0/Qty IRB 7600/Qty Art. no.

Hydraulic pump 80Mpa (Glycerin)

b

b

3HAC 13086-2

Levelmeter 2000 kit

a

a

6369901-348

Lifting device, base

1

1

3HAC 15560-1

Lifting device, manipulator

1

1

3HAC 15607-1

Lifting device, upper arm

1

-

3HAC 15994-1

Lifting device, upper arm

-

1

3HAC 15536-1

Lifting eye VLBG M12

1

1

3HAC 16131-1

Lifting eye M12

2

2

3HAC 14457-3

Lifting eye M16

2

2

3HAC 14457-4

Lifting tool (chain)

1

1

3HAC 15556-1

Lifting tool, gearbox ax 2

1

-

3HAC 13698-1

Lifting tool, gearbox ax 2

-

1

3HAC 12731-1

Lifting tool, lower arm

b

b

3HAC 14691-1

Lifting tool, motor ax 1, 4, 5

1

1

3HAC 14459-1

Lifting tool, motor ax 2, 3, 4

1

1

3HAC 15534-1

Lifting tool, wrist unit

1

-

3HAC 13605-1

Lifting tool, wrist unit

-

1

3HAC 12734-1

Measuring pin

a

-

3HAC 13908-5

Mech stop ax 3

2

-

3HAC 12708-1

Mech stop ax 3

-

2

3HAC 12708-2

Press tool, ax 2 bearing

1

-

3HAC 13527-1

Press tool, ax 2 bearing

-

1

3HAC 13453-1

Press tool, ax 2 shaft

1

1

3HAC 13452-1

Press tool, balancing device shaft

1

1

3HAC 17129-1

Press tool, balancing device

1

1

3HAC 15767-1

Puller tool, balancing device shaft

1

1

3HAC 12475-1

Removal tool, wheel unit

-

1

3HAC 15814-1

Removal tool, motor M10x

2

2

3HAC 14972-1

Removal tool, motor M12x

2

2

3HAC 14631-1

Removal tool, motor M12x

2

2

3HAC 14973-1

Rotation tool

1

1

3HAC 17105-1

Sensor plate

a

1

3HAC 0392-1

Support, base

1

1

3HAC 15535-1

Sync. adapter

a

a

3HAC 13908-1

Tool set balancing device

1

-

3HAC 15943-2

Tool set balancing device

-

1

3HAC 15943-1

Turn disk fixture

a

a

3HAC 68080011GU

Washers for Mech stop axis 3

2

2

3HAA 1001-186

Note a) Calibration tools for IRB 6600/6650/7600 when CalPen is not used (standard). Note b) Special tools that may be rent from ATRP/S.

24

A

3HAC 16245-1

2 Reference information 2.1.6 Performing a leak-down test

2.1.6 Performing a leak-down test

General

After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.

Required equipment Equipment, etc.

Spare part no. Art. no.

Leakdown tester

Note

3HAC 0207-1

Leak detection spray

Procedure Step

3HAC 16245-1

Action

Note/Illustration

1.

Finish the refitting procedure of the motor or gear in question.

2.

Remove the topmost oil plug on the gear in question, and replace it with the leakdown tester . Adapters may be required, which are included in the leakdown tester kit.

3.

Apply compressed air, and raise the pressure Recommended value: 0.2 - 0.25 with the knob until the correct value is shown on bar (20 - 25 kPa) the manometer.

4.

Disconnect the compressed air supply.

5.

Wait for approx. 8-10 minutes. No pressure loss If the compressed air is signifimust be detected. cantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.

6.

Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete.

7.

Spray suspected leak areas with leak detection Art. no. specified above! spray . Bubbles indicate a leak.

8.

When the leak has been localized: take the necessary measures to correct the leak.

A

Art. no. specified above!

25

2 Reference information 2.1.7 Lifting equipment and lifting instructions

2.1.7 Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each activity instruction. However, how to use each piece of lifting equipment is not detailed in the activity instruction, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.

26

A

3HAC 16245-1

3 Unpacking 3.0.1 Pre-installation procedure

Chapter 3: Unpacking 3.0.1 Pre-installation procedure

General

This instruction is primarily intended for use when unpacking and installing the manipulator (mechanical robot) for the first time. It also contains information useful during later re-installation of the manipulator.

Checking the prerequisites for installation

The checklist below details what must be observed before proceeding with the actual installation of the manipulator: 1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation. 2. Make sure the manipulator has not been damaged, by visually inspecting the manipulator and control cabinet exterior. 3. Make sure the lifting device to be used is dimensioned to handle the weight of the manipulator as specified in Weight, manipulator on page 27. 4. If the manipulator is not to be installed directly, it must be stored as described in Storage conditions, manipulator on page 28. 5. Make sure the expected operating environment of the manipulator conforms to the specifications as described in Operating conditions, manipulator on page 28. 6. Before taking the manipulator to its installation site, make sure the site conforms to Loads on foundation, manipulator, Requirements on foundation, manipulator on page 28 and Protection classes, manipulator on page 29. 7. Before moving the manipulator, please observe Risk of tipping/Stability on page 34 regarding risk of tipping! 8. When these prerequisites have been met, the manipulator may be taken to its installation site as described in Lifting manipulator with fork lift on page 36.

Weight, manipulator

3HAC 16245-1

The table below shows the weights of the different models:

Manipulator model

Weight

IRB 6600 - 175/2.55

1700 kg

IRB 6600 - 225/2.55

1700 kg

IRB 6600 - 175/2.8

1700 kg

IRB 6650 - 125/3.2

1725 kg

IRB 6650 - 200/2.75

1700 kg

A

27

3 Unpacking 3.0.1 Pre-installation procedure

Loads on foundation, manipulator

The table below shows the various forces and torques working on the manipulator during different kinds of operation. NOTE! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously!

Requirements on foundation, manipulator

Storage conditions, manipulator

Operating conditions, manipulator

28

Force

Endurance load (in operation)

Max. load (at emergency stop)

Force xy

±10.1 kN

±20.7 kN

Force z

18.0 ±13.8 kN

18.0 ±22.4 kN

Torque xy

±27.6 kNm

±50.6 kNm

Torque z

±7.4 kNm

±14.4 kNm

The table below shows the requirements for the foundation where the manipulator is to be fitted:

Requirement

Value

Min. levelity

0.5 mm

Max. tilt

5°

Min. resonance frequency

22 Hz

Note The limit for the maximum payload on the manipulator is reduced if the manipulator is tilted from 0°. Contact ABB for further information about acceptable payload.

The table below shows the allowed storage conditions for the manipulator:

Parameter

Value

Min. ambient temperature

-25°C

Max. ambient temperature

+55°C

Max. ambient temperature (less than 24 hrs)

+70°C

Max. ambient humidity

Max. 95% at constant temperature

The table below shows the allowed operating conditions for the manipulator:

Parameter

Value

Min. ambient temperature

+5°C

Max. ambient temperature

+50°C

Max. ambient humidity

Max. 95% at constant temperature

A

3HAC 16245-1

3 Unpacking 3.0.1 Pre-installation procedure

Protection classes, manipulator

3HAC 16245-1

The table below shows the protection class of the manipulator:

Equipment

Protection class

Manipulator, IRB 6600/6650

IP 67

A

29

3 Unpacking 3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55

3.0.2 Working range, IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55

Illustration

The illustration below shows the unrestricted working range of IRB 6600 - 175/2.55 and IRB 6600 - 225/2.55:

IR B 6600-175/2,55 IR B 6600-225/2,55

903

1119 1814

2550

xx0200000025

30

A

3HAC 16245-1

3 Unpacking 3.0.3 Working range, IRB 6600 - 175/2.8

3.0.3 Working range, IRB 6600 - 175/2.8

Illustration

The illustration below shows the unrestricted working range of IRB 6600 - 175/2.8:

IR B 6600-175/2,8

1004

1324 2061

2800

xx0200000026

3HAC 16245-1

A

31

3 Unpacking 3.0.4 Working range, IRB 6650 - 125/3.2

3.0.4 Working range, IRB 6650 - 125/3.2

Illustration

The illustration below shows the unrestricted working range of IRB 6650 - 125/3.2:

IRB 6650-125/3.2

xx0200000338

32

A

3HAC 16245-1

3 Unpacking 3.0.5 Working range, IRB 6650 - 200/2.75

3.0.5 Working range, IRB 6650 - 200/2.75

Illustration

The illustration below shows the unrestricted working range of IRB 6650 - 200/2.75:

RB 6650-200/2.75

xx0200000339

3HAC 16245-1

A

33

3 Unpacking 3.0.6 Risk of tipping/Stability

3.0.6 Risk of tipping/Stability

Risk of tipping

When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. Moving the arms will displace the centre of gravity, which may cause the manipulator to tip over. DO NOT change the manipulator position before securing it to the foundation.

Stabililty

The figure below shows the manipulator in its shipping position, which also is its most stable position.

° 50

m xx0100000103

1. DO NOT change the manipulator position before securing it to its foundation. The shipping position is the most stable.

34

A

3HAC 16245-1

4 On-site Installation

Chapter 4: On-site Installation

3HAC 16245-1

A

35

4 On-site Installation 4.1.1 Lifting manipulator with fork lift

Section 4.1: On-site installation, manipulator 4.1.1 Lifting manipulator with fork lift

General

The manipulator may be moved using a fork lift. Special aids are available. This section applies to the IRB 7600 as well as IRB 6600.

Different designs

There are two different versions of the fork lift that fit one design of the frame respectevily. The different designs of the frame and of the fork lift attachments are shown in the figure below. Determine which fork lift set fits the current manipulator. Note! The distance between the attachment holes for the fork lift pockets, shown in the figure below, are different depending on the design of the frame. This means that the fork lift sets are unique for one type of frame, they are in other words not compatible! Except for the shorter distance between the attachment holes, the later design of the frame also includes an extra oil plug, located as shown in the figure below.

C

1

2 A

B

xx0200000386

1

Frame version without oil plug on the side (C), fork lift set to be used: 3HAC 0604-2

2

Frame version with oil plug on the side (C), fork lift set to be used: 3HAC 0604-1

A

Attachment holes, fork lift 3HAC 0604-2

B

Attachment holes, fork lift 3HAC 0604-1

C

Oil plug

Required equipment

36

Equipment, etc.

Art. no.

Note

Fork lift set, incl. all required hardware

3HAC 0604-2

See Illustration, 3HAC 0604-2 on page 37.

Fork lift set, incl. all required hardware

3HAC 0604-1

See Illustration, 3HAC 0604-1 on page 38.

A

3HAC 16245-1

4 On-site Installation 4.1.1 Lifting manipulator with fork lift

Illustration, 3HAC 0604-2

Equipment, etc.

Art. no.

Note

Standard toolkit

3HAC 15557-1 The contents are defined in section Standard toolkit on page 18.

The figure below shows how to attach the fork lift set, 3HAC 0604-2, to the manipulator.

A

C B

xx0100000102

3HAC 16245-1

A

Securing screws (2x4 pcs)

B

Fork lift pockets (2 pcs)

C

Spacer (2 pcs)

A

37

4 On-site Installation 4.1.1 Lifting manipulator with fork lift

Illustration, 3HAC 0604-1

The figure below shows how to attach the fork lift set, 3HAC 0604-1, to the manipulator.

D

E

C

A B

C

A

xx0200000379

Lifting the manipulator with fork lift

A

Fork lift pocket (2 pcs, different from each other)

B

Spacer (2 pcs)

C

Securing screws (2x4 pcs), not oil lubricated

D

Securing screws (2 pcs), oil lubricated

E

Attachment point for spacer

The section below details how to secure the fork lift set to the manipulator in order to lift and move the manipulator using the fork lift ONLY! The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!

The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned accordingly!

The shorter fork lift pocket weighs 22 kg while the longer version weighs 60 kg! Use a suitable lifting device to avoid injury to personnel!

38

A

3HAC 16245-1

4 On-site Installation 4.1.1 Lifting manipulator with fork lift

No personnel must under any circumstances be present under the suspended load!

Step

Info/Illustration

Make sure the manipulator is posiRelease the brakes if required as detailed in tioned as shown in the figure to the Manually releasing the brakes on page 44. right. If it is not, position it that way. Note! Depending on which fork lift set 50° is used, the manipulator may or may not be equipped with a load, see figures on the right!

10°

1.

Action

m xx0200000079

When using fork lift set 3HAC 0604-2, no load is permitted on the manipulator!

10°

50°

m xx0200000387

When using fork lift set 3HAC 0604-1, a load is permitted on the manipulator!

3HAC 16245-1

2.

Fit the two spacers to the manipulator Shown in the figures Illustration, 3HAC and secure. 0604-2 on page 37 or Illustration, 3HAC 0604-1 on page 38!

3.

Secure the fork lift pocket horizontally to the spacers with four washers and securing screws. Notice the tightening torques! All the securing screws are identical, but they are secured with different tightening torques!

A

Shown in the figure Illustration, 3HAC 06042 on page 37 or Illustration, 3HAC 0604-1 on page 38! 4 pcs; M16x60; tightening torque: 60 Nm ±12 Nm (not oil lubricated screws). Make sure the original screws are always used (or replacements of equivalent quality: M16, quality 12.9)!

39

4 On-site Installation 4.1.1 Lifting manipulator with fork lift

Step

Action

Info/Illustration

4.

Secure the fork lift pocket vertically by fastening the two washers and oil lubricated securing screws to the frame (only in fork lift set 3HAC 06041!).

Shown in the figure Illustration, 3HAC 06041 on page 38! 2 pcs; M16x60; tightening torque: 300 Nm ±45 Nm. Make sure the original screws are always used (or replacements of equivalent quality: M16, quality 12.9)!

5.

Secure the second fork lift pocket on Shown in figure Illustration, 3HAC 0604-2 the other side of the manipulator with on page 37 or Illustration, 3HAC 0604-1 on securing screws. page 38! 4 pcs; M16x60; tightening torque: 60 Nm ±12 Nm (not oil lubricated screws). Make sure the original screws are always used (or replacements of equivalent quality: M16, quality 12.9)!

6.

Double-check that the pockets are properly secured to the manipulator! Insert the fork lift forks into the pockets and carefully lift the manipulator.

xx0200000380

Reposition the harness, if any, before using a fork lift! 7.

40

Lift the manipulator and move it to its installation site.

A

3HAC 16245-1

4 On-site Installation 4.1.2 Lifting manipulator with roundslings

4.1.2 Lifting manipulator with roundslings

General

The manipulator may be lifted with roundslings according to the illustration below. The illustration is the same as the label attached to the manipulator´s lower arm.

L IF T ING OF R OB OT HE B E N DE S R OB OT E R S L E VAGE DU R OB OT IRB 6600: m=1700kg, 3750lbs

Roundsling, 2000kg Do not strech! Rundschlingen, 2000kg Nicht gespannt! Élingue ronde, 2000kg Ne doivent pas etre sous tension!

50

m .

10

700-725 3x Chain sling with shortener,

4250kg, 0.47m, 0.54m, 0.76m. 3x Anschlagketten mit Verkürzer, 4250kg, 0.47m, 0.54m, 0.76m. 3x Chaîne avec crochet raccourcisseur, 4250kg, 0.47m, 0.54m, 0.76m.

3x Roundsling, 2000kg, 2m. 3x Rundschlingen, 2000kg, 2m. 3x Élingue ronde, 2000kg, 2m.

3HAC 16487-1 xx0200000282

-

3HAC 16245-1

Label for lifting of robot, IRB 6600

A

41

4 On-site Installation 4.1.3 Lifting manipulator with lifting slings

4.1.3 Lifting manipulator with lifting slings

General

The section below applies to IRB 7600 as well as IRB 6600.

Illustration, lifting slings

The figure below shows how to lift the complete manipulator with lifting slings. Note the recommended manipulator position shown in the following figure and in the instruction! Attempting to lift a manipulator in any other position may result in the manipulator tipping over, causing severe damage or injury!

A

D

C

D

F

C E I

L B xx0200000153

42

A

Load hook

B

Swivelling lifting eyes, 4 pcs

C

Shortening hook

D

Chain

E

M12 lifting eye

F

Lifting device´s eye

I

Lifting slings, 4 pcs

L

Hook

A

3HAC 16245-1

4 On-site Installation 4.1.3 Lifting manipulator with lifting slings

Required equipment Equipment

Art. no.

Lifting device, manipulator 3HAC 15607-1, includes instruction, 3HAC 15971-2, for how to use the lifting device.

Slings attached directly onto manipulator

The section below details how to lift and move the manipulator using lifting slings when these are to be attached directly onto the manipulator frame.

The IRB 6600/6650 manipulator weighs 1725 kg! All lifting equipment used must be dimensioned accordingly!

The IRB 7600 manipulator weighs 2550 kg! All lifting equipment used must be dimensioned accordingly!

No personnel must under any circumstances be present under the suspended load!

Step

Action

Note

1.

Run the overhead crane to a position above the manipulator.

2.

Make sure the manipulator is positioned Release the brakes if required as as shown in the figure on the right. If it is detailed in Manually releasing the brakes on page 44. not, position it that way. ° 50

m xx0100000103

3HAC 16245-1

3.

Fit the lifting device, manipulator to the robot as described in the enclosed instruction!

4.

Raise the overhead crane to lift the robot. Make sure all hooks and attachments maintain their correct positions while lifting the manipulator! Always move the manipulator at very low speeds, making sure it does not tip.

A

Art. no. specified in Required equipment on page 43!

43

4 On-site Installation 4.1.4 Manually releasing the brakes

4.1.4 Manually releasing the brakes

General

The section below details how to release the holding brakes of each axis motor. It applies to IRB 7600 as well as IRB 6600/6650. Differences between the versions are highlighted in the affected sections. The brakes may be released by: •

Internal brake release unit: using push buttons on the manipulator. This requires either that the controller is connected or that power is supplied to the R1.MP connector (on manipulator base), 0V on pin 12 and 24V on pin 11.

•

IRB 7600: External brake release unit: using push-buttons on an external brake release unit. This does NOT require the controller to be connected. The external unit is used when there are no push-buttons on the manipulator.

Supplying power on the wrong pins may cause all brakes on the manipulator to be released!

Illustration, IRB 6600/6650

The internal brake release unit on the IRB 6600/6650 is located at the frame, as shown in the figure below.

6 5 4 3 2 1

xx0300000044

-

44

Internal brake release unit with push buttons, located on the manipulator frame

A

3HAC 16245-1

4 On-site Installation 4.1.4 Manually releasing the brakes

Illustration, IRB 7600 base

The internal brake release unit on the IRB 7600 is located either at the base or at the frame. The figure below shows the unit located at the base.

xx0200000375

-

Illustration, IRB 7600 frame

Internal brake release unit with push buttons, located on the manipulator base

The internal brake release unit on the IRB 7600 is located either at the base or at the frame. The figure below shows the unit located at the frame.

6 5 4

3 2 1

xx0200000376

-

3HAC 16245-1

Internal brake release unit with push buttons, located on the manipulator frame

A

45

4 On-site Installation 4.1.4 Manually releasing the brakes

Internal brake release unit, releasing the brakes

The procedure below details how to release the holding brakes when the robot is equipped with an internal brake release unit.

When relasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!

Step

Illustration, IRB 7600 external brake release unit connections

Action

Info/Illustration

1.

The internal brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.

The buttons are located according to one of the figures -Illustration, IRB 6600/6650 on page 44, - Illustration, IRB 7600 base on page 45 or - Illustration, IRB 7600 frame on page 45.

2.

Release the holding brake on a particular manipulator axis by pressing the corresponding button on the internal brake release panel. The brake will function again as soon as the button is released.

The illustration below shows where to connect the external brake release unit in order to release the manipulator’s holding brakes.

B

A

C D

xx0100000104

46

A

Connector R1.BU

B

Rear connector plate

C

Rear cover plate

D

External brake release unit

A

3HAC 16245-1

4 On-site Installation 4.1.4 Manually releasing the brakes

Illustration IRB 7600, external brake release unit connectors

The illustration below shows the connectors on the manipulator and on the external brake release unit.

A

B

C

D E

xx0200000081

A

Rear connector plate

B

Connector R1.MP

C

Connector R1.BU

D

External brake release unit

E

Connect to R1.BU

Required equipment

External brake release unit (only IRB 7600)

Equipment

Art. no.

External brake release unit

3HAC 12987-1

This section details how to release the holding brakes when the robot is equipped with an external brake release unit (only IRB 7600).

When releasing the holding brakes, the manipulator axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the manipulator arm!

Step 1.

3HAC 16245-1

Action

Info/Illustration

Remove the rear cover plate on the base of Shown in Illustration, IRB 7600 exterthe manipulator by unscrewing its attachnal brake release unit connections on ment screws and plain washers page 46!

A

47

4 On-site Installation 4.1.4 Manually releasing the brakes

Step

48

Action

Info/Illustration

2.

Locate the free connector, connected to the Shown in Illustration IRB 7600, exterrear of connector R1.MP behind the rear nal brake release unit connectors on connector plate. page 47! Make sure it is designated R1.BU.

3.

Connect the external brake release unit to connector R1.BU.

4.

Release the holding brake of each manipulator axis by pressing the respective button on the external brake release unit.

5.

Disconnect the external brake release unit.

6.

Refit the rear cover plate with its attachment screws.

A

Art. no. specified in section Required equipment on page 47! Shown in Illustration IRB 7600, external brake release unit connectors on page 47!

3HAC 16245-1

4 On-site Installation 4.1.5 Lifting the base plate

4.1.5 Lifting the base plate

General

This section details how to lift the base plate

Equipment

Spare part no. Art. no.

Note

Standard toolkit

3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!

Lifting eye, M16

3HAC 14457-4 Use three lifting eyes. For lifting the base plate.

Lifting slings

Use three slings. Length: approx. 2 m

Hole configuration

A

xx0200000096

A

Attachment holes for lifting eyes (x3)

The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!

Lifting the base plate Step

3HAC 16245-1

Action

Info/Illustration

1.

Fit lifting eyes in the three lifting holes. Shown in the figure Hole configuration on page 49!

2.

Fit lifting slings to the eyes and to the lifting device.

A

49

4 On-site Installation 4.1.6 Securing the base plate

4.1.6 Securing the base plate

General

This section details how to secure the base plate.

Base plate, dimensions

2x 503 2x 453 2x 247 2x 182 2x 90 2x 90

2x 451 2x 407 2x 321 2x 273

D

B B

455

A A

540

480

A-A B- B

D

xx0100000105

50

A

3HAC 16245-1

4 On-site Installation 4.1.6 Securing the base plate

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.

B

A

B

A

B xx0300000045

A

Guide sleeve holes

B

Orienting grooves in the base plate

Required equipment Equipment

Spare part no. Art. no.

Base plate

3HAC 12937-7 Includes all required guide sleeves, screws and washers. A drawing of the base plate itself may be ordered from ABB Robotics!

Guide sleeves, 2 pcs (between guide plate and manipulator)

3HAC 12937-3 Included in Base plate, 3HAC 12937-7.

Standard toolkit

3HAC 15571-1 The contents are defined in section Standard toolkit on page 18!

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

3HAC 16245-1

Note

These procedures include references to the tools required.

A

51

4 On-site Installation 4.1.6 Securing the base plate

Base plate

This section details how to secure the base plate to the foundation. The table specifies any recommendations made by ABB:

Variable

Recommendation

Recommended foundation quality 1

Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm

Recommended foundation quality 2

Sturdy concrete foundation, double reinforced by ø10 mm steel bars, distance 140 mm, class K25, t=250

Recommended bolt quality and dimen- Hilti HDA-P, M20 x 200 sion The base plate weighs 335 kg! All lifting equipment used must be dimensioned accordingly!

Step

52

Action

Info/illustration

1.

Make sure the foundation is level.

2.

Orient the base plate in relation to the robot work location using the three grooves in the base plate.

3.

Lift the base plate to its mounting position. Detailed in Lifting the base plate on page 49.

4.

Use the base plate as a template and drill If possible, observe the recommenda16 attachment holes as required by the tions specified in the table above. ABB selected bolt dimension. does not assume any responsibility for other foundation qualities, due to great variations in the foundation properties.

5.

Fit the base plate and use the levelling bolts to level the base plate.

6.

If required, fit strips of sheet metal underneath the base plate to fill any gaps.

7.

Secure the base plate to the foundation with screws and sleeves.

8.

Recheck the four manipulator contact sur- Max. allowed deviation: 0.5 mm faces on the base plate to make sure they are level and flat. If they are not, pieces of sheet metal or similar may be used to bring the base plate to a level position.

A

Shown in Base plate, grooves and holes on page 51.

3HAC 16245-1

4 On-site Installation 4.1.7 Orienting and securing the manipulator

4.1.7 Orienting and securing the manipulator

General

This section details how to orient and secure the manipulator to the base plate after fitting it to the foundation, in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures. The section below applies to IRB 7600 as well as IRB 6600/6650. The only difference between these robot models is that IRB 7600 is secured using 12 attachment bolts while IRB 6600/6650 uses 8 attachment bolts.

Illustration, manipulator fitted to base plate

The illustration below shows the IRB 7600 manipulator base fitted to the base plate. The IRB 6600/6650 manipulator base does not have the attachment holes A (4 pcs).

A B

C

D

B

xx0100000107

Attachment screws

3HAC 16245-1

A

Manipulator attachment bolts and washers, 4 pcs M24 x 120 (IRB 7600 only)

B

Manipulator attachment bolts and washers, 8 pcs M24 x 120

C

Levelling screws

D

Base plate attachment screws

The table below specifies the type of securing screws and washers to be used for securing the manipulator to the base plate/foundation.

Suitable screws, lightly lubricated:

M24 x 120

Quality

Quality 8.8

Suitable washer:

Thickness: 4 mm Outer diameter: 44 mm Inner diameter: 25 mm

Tightening torque:

775 Nm

A

53

4 On-site Installation 4.1.7 Orienting and securing the manipulator

Securing the manipulator

The procedure below details how to secure the manipulator to the base plate after fitting the plate to the foundation.

Step

Hole configuration, IRB 6600/ 6650

Action

Info/Illustration

1.

Lift the manipulator.

Detailed in Lifting manipulator with fork lift on page 36or Lifting manipulator with lifting slings on page 42.

2.

Move the manipulator to the vicinity of its installation location.

3.

Fit two guide sleeves to the guide sleeve Shown in Base plate, grooves and holes holes in the base plate. on page 51. Note that one of the guide sleeve holes is elongated!

4.

Guide the manipulator gently using two M24 screws while lowering it into its mounting position.

Make sure the manipulator base is correctly fitted onto the guide sleeves!

5.

Fit the bolts and washers in the base attachment holes.

Specified in Attachment screws on page 53. Shown in the figure Illustration, manipulator fitted to base plate on page 53! Note! Lightly lubricate the 8 or 12 screws before assembly!

6.

Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted.

The illustration below shows the hole configuration used when securing the manipulator, IRB 6600.

R400 4 x ° 15

7,5° 4x3

xx0200000029

54

A

3HAC 16245-1

4 On-site Installation 4.1.7 Orienting and securing the manipulator

Hole configuration, IRB 7600

The illustration below shows the hole configuration used when securing the manipulator, IRB 7600. 4x

10

4 5 .5 x1 x7 4

4x 37.5

xx0300000046

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.

xx0100000109

3HAC 16245-1

A

55

4 On-site Installation 4.1.8 Fitting equipment on manipulator

4.1.8 Fitting equipment on manipulator

General

The manipulator features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc, fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell. Under certain conditions, mounting holes may be added on the manipulator.

Illustration, fitting extra equipment on lower arm

The illustration below shows the mounting holes available for fitting extra equipment on the lower arm. Make sure not to damage the manipulator cabling on the inside of the lower arm when fitting extra equipment. Always use the appropriate attachment screws! 202 207,5*

282 154

M12 (4x) 80

125 25 110* 40*

5, 35* 75 150

53

354, 369*

xx0200000195

*

Illustration, fitting extra equipment on upper arm

IRB 6650

The illustration below shows the mounting holes available for fitting extra equipment on the upper arm.

M12 (4x)

190

xx0200000196

56

A

3HAC 16245-1

4 On-site Installation 4.1.8 Fitting equipment on manipulator

Illustration, fitting extra equipment on frame

The illustration below shows the mounting holes available for fitting extra equipment on the frame.

75

200

45 240 4x M16

790 1195 xx0200000198

3HAC 16245-1

A

57

4 On-site Installation 4.1.8 Fitting equipment on manipulator

Illustration, fitting on mounting flange

The illustrations below show the mounting holes available for fitting equipment on the mounting flange. There are two different versions of the mounting flange, as shown in illustrations below. A 30° (11x) 15 Ø12 H7 Depth 15

B

B

A A-A

Ø100 H7Depth 8 min Ø 160 B -B xx0200000197

-

58

Mounting flange for robot version 225/2.55, 175/2.8, 125/3.2 and 200/2.75

A

3HAC 16245-1

4 On-site Installation 4.1.8 Fitting equipment on manipulator

A 30° (12 x) 15

Ø12 H7 Depth 15

B

B

A

Ø100H7 Depth 8min Ø160 xx0200000397

-

Fastener quality

3HAC 16245-1

Mounting flange for robot version 175/2.55

When fitting tools on the mounting flange (see the figures above), use only screws with quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.

A

59

4 On-site Installation 4.1.9 Loads

4.1.9 Loads

General

Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of center of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operational stops may result.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the Product Specification. The loads must also be defined in the software as detailed in User’s Guide.

Stop time and braking distances

Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB Robotics.

60

A

3HAC 16245-1

4 On-site Installation 4.2.1 Introduction

Section 4.2: Restricting the working range 4.2.1 Introduction

General

The working range of the manipulator may be limited to eliminate the risk of collisions. The following axes may be restricted: •

Axis 1, hardware (mechanical stop) and software (signal from adjustable position switch)

•

Axis 2, hardware (mechanical stop) and software (signal from adjustable position switch)

•

Axis 3, hardware (mechanical stop) and software (signal from adjustable position switch)

This section describes the utilization of the mechanical stops and the position switches.

3HAC 16245-1

A

61

4 On-site Installation 4.2.2 Mechanically restricting the working range of axis 1

4.2.2 Mechanically restricting the working range of axis 1

General

The working range of axes 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation in both directions.

Mechanical stops, axis 1

The illustration below shows the mounting position of the mechanical stops on axis 1.

A

B xx0300000049

A

Additional mechanical stop

B

Fixed mechanical stop

Required equipment Equipment, etc.

62

Spare part no. Art. no.

Note

7.5°, mechanical stop for axis 1

3HAC 11076-1 Includes attachment screws.

15°, mechanical stop for axis 1

3HAC 11076-2 Includes attachment screws.

Standard toolkit

3HAC 15571-1 The contents are defined in the section Standard toolkit on page 18.

A

3HAC 16245-1

4 On-site Installation 4.2.2 Mechanically restricting the working range of axis 1

Installation, mechanical stops axis 1

The procedure below details how to mount the mechanical stops on axis 1. An assembly drawing is also enclosed with the product.

The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed!

Step

3HAC 16245-1

Action

Note/Illustration

1.

Mount the additional mechanical stop on the frame according to the figure Mechanical stops, axis 1 on page 62.

Tightening torque: 115 Nm.

2.

The software working range limitations must be amended to correspond to the changes in the mechanical limitations of the working range.

A

63

4 On-site Installation 4.2.3 Mechanically restricting the working range of axis 2

4.2.3 Mechanically restricting the working range of axis 2

General

The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.

Mechanical stops, axis 2

The illustration below shows the mounting position of the mechanical stops on axis 2.

A B

xx0300000047

A

Additional mechanical stops

B

Fixed mechanical stop

Required equipment Equipment, etc.

64

Spare part no. Art. no.

Note

Mechanical stop set, axis 2 IRB 6600/6650

3HAC 13787-1 Includes six stops, 3HAC 137861, each one restricting the working range by 15°. Includes attachment screws.

Mechanical stop set, axis 2 IRB 7600

3HAC 11077-1 Includes six stops, 3HAC 114071, each one restricting the working range by 15°. Includes attachment screws.

Standard toolkit

3HAC 15571-1 The contents are defined in section Standard toolkit on page 18.

A

3HAC 16245-1

4 On-site Installation 4.2.3 Mechanically restricting the working range of axis 2

Installation, mechanical stops axis 2

The procedure below details how to mount the mechanical stops on axis 2. An assembly drawing is also enclosed with the product.

The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed!

Step

3HAC 16245-1

Action

Note/Illustration

1.

Mount and tighten the additional stops in a row, Tightening torque: 115 Nm. starting from the fixed stop. Shown in the figure Mechanical stops, axis 2 on page 64.

2.

The software working range limitations must be amended to correspond to the changes in the mechanical limitations of the working range.

A

65

4 On-site Installation 4.2.4 Mechanically restricting the working range of axis 3

4.2.4 Mechanically restricting the working range of axis 3

General

The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.

Mechanical stops, axis 3

The illustration below shows the mounting position of the mechanical stops on axis 3.

A

B

xx0300000048

A

Additional mechanical stops

B

Fixed mechanical stop

Required equipment Equipment, etc.

66

Spare part no. Art. no.

Note

Mechanical stop set, axis 3, IRB 6600/6650

3HAC 13128-1 Includes six stops, one with 80°restriction, 3HAC 12708-3 (use when limitation angle >=80), and five with 20°, 3HAC 12708-1. Includes attachment screws.

Mechanical stop set, axis 3, IRB 7600

3HAC 13128-3 Includes six stops, one with 80°restriction, 3HAC 12708-4 (use when limitation angle >=80), and five with 20°, 3HAC 12708-2. Includes attachment screws.

Standard toolkit

3HAC 15571-1 The contents are defined in the section Standard toolkit on page 18.

A

3HAC 16245-1

4 On-site Installation 4.2.4 Mechanically restricting the working range of axis 3

Installation, mechanical stops axis 3

The procedure below details how to mount the mechanical stops on axis 3. An assembly drawing is also enclosed with the product.

The addititonal mechanical stop must be replaced after a hard collision if the mechanical stop has been deformed!

Step

3HAC 16245-1

Action

Note/Illustration

1.

Mount and tighten the additional stops in a row, starting from the fixed stop.

Shown in the figure Mechanical stops, axis 3 on page 66 Tightening torque: 115 Nm.

2.

The software working range limitations must be amended to correspond to the changes in the mechanical limitations of the working range.

A

67

4 On-site Installation 4.2.5 Position switches

4.2.5 Position switches

General

Position switches can be installed on axes 1-3. The position switches include cams as shown in the figures below (all illustrations show IRB 7600 unless otherwise stated). The position switch kits may be delivered in one of two ways:

Axis 1

•

Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.

•

As kits to be completely fitted to the manipulator and adjusted by the user.

Description

Art. no.

Position switch, axis 1 complete

3HAC 14118-1

Position switch, axis 2 complete

3HAC 15710-1

Position switch, axis 3 complete

3HAC 15709-1

The illustration below shows the position switch for axis 1:

A F C

D

B

E xx0100000158

68

A

Position switch, axis 1

B

Cam

C

Set screw, cam (cam stop)

D

Protection sheet

E

Rail

F

Rail attachment

A

3HAC 16245-1

4 On-site Installation 4.2.5 Position switches

Axis 2

The illustration below shows the position switch for axis 2:

E B

A

C F xx0100000159

3HAC 16245-1

A

Position switch, axis 2

B

Cam

C

Set screw, cam (cam stop)

E

Rail

F

Rail Attachment

A

69

4 On-site Installation 4.2.5 Position switches

Axis 3

The illustration below shows the position switch for axis 3:

F

E

C B

A

xx0100000160

Specifications

Connections

70

A

Position switch, axis 3

B

Cam

C

Set screw, cam (cam stop)

E

Rail

F

Rail attachment

Maximum voltage/current for the position switches:

Parameter

Value

Voltage

Max. 50 V DC

Current

Max. 1 A

The position switches may be connected to different points on the robot system: •

R1.SW1 at the manipulator base. Customer connection kit is recommended! Also see "Customer Connection Kit"!

•

R1.SW2/3 at the manipulator base. Customer connection kit is recommended! Also see "Customer Connection Kit"!

•

XT8, screw terminal in the controller cabinet

A

3HAC 16245-1

4 On-site Installation 4.2.5 Position switches

Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switches:

Step

Illustration, adjust and secure cams

Action

Info/Illustration

1.

Cut the cam to a suitable length.

Use a sharp knife and rubber hammer or similar.

2.

Cut the edge of the cam edge to max 30°!

Shown in Illustration, cutting the cam on page 72. If the angle is larger, this may damage the position switch!

3.

Cut the part of the cam running in the profile to 90°! Also see Illustration, cutting the cam on page 72 below!

4.

Make sure the ends of the profile are chamfered to enable the cam to run through the profile.

5.

Fit the cam with the M5 screw and nut. Tighten Shown in Illustration, adjust and the M5 screw to secure the cam. secure cams on page 71.

The illustration below show how to adjust and secure the position switch cams and profiles.

C 30°

A

B

xx0100000113

3HAC 16245-1

A

Cam stop, M5 nut and M5 x 6 set screw

B

Adjustable cam

C

Profile

A

71

4 On-site Installation 4.2.5 Position switches

Illustration, cutting the cam

The illustration below show how to cut the position switch cam.

A

o 30 o 90

xx0100000114

A

72

Remove the gray section

A

3HAC 16245-1

4 On-site Installation 4.3.1 Lifting the controller cabinet

Section 4.3: On-site installation, controller cabinet 4.3.1 Lifting the controller cabinet

Lifting device

Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet S4Cplus M2000A as shown below.

60°

xx0100000153

3HAC 16245-1

A

Min. 60°when lifting with straps

B

Fork lift

A

73

4 On-site Installation 4.3.2 Required installation space, control cabinet

4.3.2 Required installation space, control cabinet

Dimensions

The figure below shows the required installation space for the S4Cplus M2000A control cabinet:

A A xx0100000156

A

Dimensions

Min. distance from wall

The figure below shows the bolt pattern for the S4Cplus M2000A control cabinet:

720

400

xx0100000157

74

A

3HAC 16245-1

5 Electrical connections

Chapter 5: Electrical connections

3HAC 16245-1

A

75

5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet

Section 5.1: Signal/Power cables 5.1.1 Connecting the manipulator to the control cabinet

General

Connect the manipulator and control cabinet to each other after securing them to the foundation. The lists below specify which cables to be used in each application.

Location of connectors

XS

Application interface

XS20

I/O connections

XS8

External axes in separate cabinet

X13/X5

Operator’s panel

XS78

Safety signals, external connections

XS77/X7

DeviceNet

LAN/XTDF

Mains connection

X24VE/VS

External axes

IBS

Position switches

XS41

Manipulator cables

XS58 XS2 Ext. contr. panel

Main cable categories

All cables between manipulator and control cabinet are divided into the following categories:

Cable category

Description

Manipulator cables

Handles power supply to and control of the manipulator’s motors as well as feedback from the serial measurement board.

Position switch cables (option) Handles supply to and feedback from any position switches and cooling fans on the manipulator.

76

Customer cables (option)

Handles communication with equipment fitted on the manipulator by the customer, including databus communication, low voltage signals and high voltage power supply + protective earth.

External axes cables (option)

Handles power supply to and control of the external axes’ motors as well as feedback from the servo system.

A

3HAC 16245-1

5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet

These categories are divided into sub-categories which are specified below:

Manipulator cables

These cables are included in the standard delivery. They are completely premanufactured and ready to plug in.

Cable subcategory

Connection Connection point, point, cabinet manipulator

Description

Manipulator cable, power

Transfers drive power from the drive XP1 units in the control cabinet to the manipulator motors.

R1.MP

Manipulator cable, signals

Transfers resolver data from the serial measurement board and power supply to the SMB.

R1.SMB

XP2

Manipulator cable, power Cable

Article number

Manipulator cable, power, 7 m

3HAC 11818-1

Manipulator cable, power, 15 m

3HAC 11818-2

Manipulator cable, power, 30 m

3HAC 11818-4

Cable

Article number

Manipulator cable, signal, shielded, 7 m

3HAC 7998-1

Manipulator cable, signal, shielded, 15 m

3HAC 7998-2

Manipulator cable, signal, shielded, 30 m

3HAC 7998-4

Manipulator cable, signals

Position switch cables

3HAC 16245-1

These cables are not included in the standard delivery, but can be included in the delivery if the Position switch option is ordered. (The position switches can also be ordered without cables.) The cables are completely pre-manufactured and ready to plug in.

Cable

Article number

Connection Connection point, point, cabinet manipulator

Position switch cable, axis 1, 7 m

3HAC 13175-1

XP8

R1.SW

Position switch cable, axis 1, 15 m

3HAC 13175-2

XP8

R1.SW

Position switch cable, axis 1, 30 m

3HAC 13175-4

XP8

R1.SW

Position switch cable, axes 2 and 3, 7 m 3HAC 13176-1

XP58

R1.SW2/3

Position switch cable, axes 2 and 3, 15 m 3HAC 13176-2

XP58

R1.SW2/3

Position switch cable, axes 2 and 3, 30 m 3HAC 13176-4

XP58

R1.SW2/3

A

77

5 Electrical connections 5.1.1 Connecting the manipulator to the control cabinet

Customer cables

External axes cables

These cables are not included in the standard delivery, but can be included in the delivery of each specific option. The cables are not ready to plug in, but requires connection to terminals inside the control cabinet as well as keying. These activities are detailed in Customer Connection Kit.

Connection point, cabinet

Connection point, manipulator

3HAC 13173-1

XT/XP5.1 XT/XP6 XS6

R1.CP/CS

Fieldbus cable, CAN, 15 m

3HAC 13173-2

XT/XP5.1 XT/XP6 XS6

R1.CP/CS

Fieldbus cable, CAN, 30 m

3HAC 13173-4

XT/XP5.1 XT/XP6 XS6

R1.CP/CS

Fieldbus cable, Profibus, 7 m

3HAC 13174-1

XT/XP5.1 XT/XP6 DP/M

R1.CP/CS

Fieldbus cable, Profibus, 15 m

3HAC 13174-2

XT/XP5.1 XT/XP6 DP/M

R1.CP/CS

Fieldbus cable, Profibus, 30 m

3HAC 13174-4

XT/XP5.1 XT/XP6 DP/M

R1.CP/CS

Cable

Article number

Fieldbus cable, CAN, 7 m

These cables are not included in the standard delivery, but can be included if the External axes option is ordered. The cables are ready to plug in.

Cable sub-category Description

78

Connection Connection point, point, cabinet manipulator

External axes cable, power

Transfers drive power from the XP7 drive units in the control cabinet to the externa axes motors.

XS45

External axes cable, signals

Transfers resolver data from the serial measurement board and power supply to the SMB.

XS47

A

XP41

3HAC 16245-1

5 Electrical connections 5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A

5.1.2 Connection of manipulator cables to control cabinet, S4Cplus M2000A

General

Section "Connecting the manipulator to the control cabinet" specifies which cables to use and to which connectors these are to be connected in order to to connect the controller to the manipulator.

Connections to the cabinet

All control cabinet connectors are shown in the figure below.

xx0100000247

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

3HAC 16245-1

A

Manipulator cable (Power)

B

Manipulator cable (Signal)

A

79

5 Electrical connections 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A

5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A

General

Connect the power supply either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front. The cable connector is supplied but not the cable. Dimension the mains supply cables and fuses in accordance with the rated power and line voltage, see rating plate on the controller.

Connections to the mains switch

Also see the Circuit Diagram. The instruction below details how to make all required connections to the mains switch:

xx0100000248

A

Connector Q1 (L1, L2, L3)

B

Cable gland

C

Protective Earth connection PE

Step Action

80

Info/Illustration

1.

Remove the left cover plate under the top lid.

2.

Pull the mains cable (outer diam. 10.2 mm) through the gland located on the left cabinet wall.

3.

Release the connector from the knob by pushing the release buttons located on the side of the connector.

A

Shown in the figure above!

3HAC 16245-1

5 Electrical connections 5.1.3 Connection of mains power to control cabinet, S4Cplus M2000A

Step Action 4.

Connection through a power socket

Info/Illustration

Connect phase: • 1 to L1 (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 theprotective earth connection.

5.

Snap the breaker on to the knob again and check that it is fixed properly in the correct position.

6.

Tighten the cable gland.

7.

Fasten the cover plate.

Shown in the figure above! NOTE! Max. conductor size is 6 mm2 (AWG 10). Tighten to a torque of 2.3-2.5 Nm. Retighten after approx. 1 week.

It is also possible to connect the mains supply through an optional wall socket of type 3x32A or 4x32A or via an industrial Harting connector (DIN 41 640). See the figure below. Cable connectors are supplied (option 132 - 134).

A xx0100000162

A

3HAC 16245-1

DIN connector

A

81

5 Electrical connections 5.2.1 Signal Classes

Section 5.2: Signal connections 5.2.1 Signal Classes

Overview

Signals

82

Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.

•

Power Signals: 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.

A

3HAC 16245-1

5 Electrical connections 5.2.2 Selecting Cables

5.2.2 Selecting Cables

Controller cables:

All cables laid in the controller must be capable of withstanding 70o C. In addition.

Power Signal:

Shielded cable with an area of at least 0.75mm2 or AWG 18. Note that any local standards and regulations concerning insulation and area must always be complied with.

Control signals:

Shielded cables.

Measuring signals:

Shielded cable with twisted pair conductors.

Data communication signals:

Shielded cable with twisted pair conductors.

A specific cable should be used for Gateway (Fiel bus) connections.

CAN bus with DeviceNet for distributing I/O units:

Thin cable according to DeviceNet specification release 1.2, must be used, e.g. ABB article no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply and two for signal transmission. Note that a separate cable for supply of I/O loads is required.

Allen-Bradley Remote I/O:

Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connections between DSQC 350 and the Allen-Bradley PLC bus.

Interbus-S:

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

Profibus DP:

Cables according to Profibus DP specification should be used for connections between the I/ O unit DSQC 352 and the external Profibus DP bus.

Ethernet:

Shielded twisted pair conductors (10 Base T STP).

3HAC 16245-1

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83

5 Electrical connections 5.2.3 Interference elimination

5.2.3 Interference elimination

External units

External relay coils, solenoids, and other units that will be connected to the controller must be neutralized. The figure below illustrates how this can be done. The turn-off time for DC relays increases after neutralisation, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of the switches that control them

Clamping with a diode

The diode should be be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage. +24V

0V

xx0100000163

Clamping with a varistor

The varistor should be be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage. +24V

0V

xx0100000164

Clamping with an RC circuit

R 100 ohm, 1W C 0.1 - 1 mF. >500V max. voltage, 125V nominal voltage. +24V DC, or AC voltage

R

C

0V

xx0100000165

84

A

3HAC 16245-1

5 Electrical connections 5.2.4 Connection types

5.2.4 Connection types

General

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

Connections

3HAC 16245-1

Designation

Connection type

X(T)

Screw terminal

XP

Pin (male)

XS

Sockets (female)

A

85

5 Electrical connections 5.2.5 Connections to screw terminals

5.2.5 Connections to screw terminals

Overview

This section describes how to connect conductors to screw terminals. Detailed information about connection location and functions will be found in the circuit diagram (Service Manual).

Installation

The installation should comply with the IP54 (NEMA 12) protective standard. 1. Bend unused conductors backwards and attach them to the cable using a clasp, or similar. To prevent interference, ensure that unused conductors are not connected at the other end of the cable (antenna effect) In environments with much interference, disconnected conductors should be grounded (0V) at both ends.

86

A

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5 Electrical connections 5.2.6 Connections to connectors (option)

5.2.6 Connections to connectors (option)

Location of connectors

The industrial connectors can be found on the front of the control cabinet. See the figure below and the figure in section "Control cabinet connections manipulator"! The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included).

xx0100000249

XS

Application interface

XS20

I/O connections

XS8

External axes in separate cabinet

X13/X5

Operator’s panel

XS78

Safety signals, external connections

XS77/X7

DeviceNet

LAN/XTDF

Mains connection

X24VE/VS

External axes

IBS

Position switches

XS41

Manipulator cables

XS58 XS2 Ext. contr. panel

Connectors, description

Each industrial connector has accomodations for four rows of 16 conductors with a maximum conductor area of 1.5 mm 2 . The pull-relief clamp must be used when connecting the shield to the case.

Making the connection

The section below details how to crimp cable connections to pins: 1. Using a special crimp tool, crimp a pin or socket on to each non-insulated conductor. When two conductors are be connected to the same pin or socket, both of them must be crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.

2. Snap the pin into the connector housing. 3. Push the pin into the connector until it locks. 4. When removing pins or sockets from industrial connectors, a special extractor tool must be used.

3HAC 16245-1

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5 Electrical connections 5.3.1 Signal connections, SpotWelding Specification

Section 5.3: Customer connections on manipulator 5.3.1 Signal connections, SpotWelding Specification

General

The section below specifies the signal connections on manipulator arm housing for material handling.

Customer Power (CP) Servo motor power

3

600 VAC, 12A rms, min. 1, 5 mm 2

Utility power

4

600 VAC, 5A rms, min. 0,5 mm 2

Protective earth

1

min. 1,5 mm 2

Signals

20

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs

Sensitive signals

10

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs + extra screening

Bus signals

2

Profibus 12 Mbit/s spec*

Bus signals

2

CAN/DeviceNet spec*

Bus signals

4

Interbus spec*

Bus utility signals

4

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs

Fibre Optics

2

1 mm Polymer fibre, wavelength 660 mm

Hose

5

Inner diameter 12,5 mm, max. working pressure 16 bar

Weld power

2

35 mm 2 , 600 VAC, Frequency 50-1000 Hz 150A rms at +20°(68 F) ambient temp. 120 A rms at +50°(122 F) ambient temp.

Protective earth

1

35 mm 2

Customer Signal (CS)

Customer BUS (CBUS)

Air/Water (PROC)

Welding power (WELD)

Further information

88

See Circuit Diagram in the "Repairs Manual, part 2" for further information.

A

3HAC 16245-1

5 Electrical connections 5.3.2 Signal connections, Material Handling Specification

5.3.2 Signal connections, Material Handling Specification

General

The section below specifies the signal connections on manipulator arm housing for material handling.

Customer Power (CP) Servo motor power

3

600 VAC, 12A rms, min. 1, 5 mm 2

Utility power

4

600 VAC, 5A rms, min. 0,5 mm 2

Protective earth

1

min. 1,5 mm 2

Signals

20

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs

Sensitive signals

10

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs + extra screening

Bus signals

2

Profibus 12 Mbit/s spec*

Bus signals

2

CAN/DeviceNet spec*

Bus signals

4

Interbus spec*

Bus utility signals

4

50 VAC/DC, 1A rms, min. AWG 24 tw.pairs

Fibre Optics

2

1 mm Polymer fibre, wavelength 660 mm

Customer Signal (CS)

Customer BUS (CBUS)

* Twisted pair under separate screen. Can also be used for very sensitive signals.

Air/Water (PROC) Hose

Further information

3HAC 16245-1

1

Inner diameter 12,5 mm, max. working pressure 16 bar

See Circuit Diagram in the "Repairs Manual, part 2" for further information.

A

89

5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit

Section 5.4: Customer connections on controller 5.4.1 The MOTORS ON/MOTORS OFF circuit

Outline diagram

The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches. The diagram shows the available customer connections, AS, GS and ES. A E C D

B

G

F

H J R

S

T

M

K

L

N P

xx0100000174

Function of the MOTORS ON/ MOTORS OFF circuit

90

A

ES (emergency stop)

B

LS (Limit switch)

C

Solid state switches

D

Contactor

E

Mains

F

Drive unit

G

Second chain interlock

H

GS (general mode safeguarded space stop)

J

AS (Automatic mode safeguarded space stop)

K

ED (TPU enabling device)

L

Manual mode

M

Motor

N

Automatic mode

P

Operating mode selector

R

RUN

S

EN1

T

EN2

The circuit monitors all safety related equipment and switches. If any of the switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.

A

3HAC 16245-1

5 Electrical connections 5.4.1 The MOTORS ON/MOTORS OFF circuit

Connection of safety chains

The diagram below shows the two-channel safety chain. Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V. Connection tables for X1-X4 are given in "External customer connections on panel X1 - X4". 24V X3:12 X4:12

Ext LIM1 24V

K1 0V

X1:11 12 ES1

X3:10

Opto GS1 isol. TPU En1

8 11

&

Opto AS1 isol.

9

Auto1

K1

EN Run

Intern locking

K2

Man1

External contactors 0V 24 V 0V

X3:3 X4:3

4 4

CONT1 CONT2

Ext LIM2 X2:11 12

K2

8

Drive Unit

ES2

X4:10

Opto GS2 isol. TPU En2

&

11 9

24 V

M

Opto AS2 isol. Auto2

Man2

xx0100000166

Technical data per chain

Connection of ES1/ES2 on panel unit

3HAC 16245-1

Limit switch

Load: 300 mV. Max. voltage drop: 1 V

External connectors

Load: 10 mA. Max. voltage drop: 4 V

GS/AS load at 24 V

25 mA

GS/AS closed "1"

>18 V

GS/AS open "0"