The IRB 2400 M98 is a 6-axis industrial robot designed for manufacturing industries that use flexible robot-based automation. It has an open structure specially adapted for flexible use and can communicate extensively with external systems. This robot is equipped with an operating system called BaseWare OS, which controls every aspect of the robot, including motion control, development and execution of application programs, communication, etc.
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3HAC 2923-1
M98
Product On-line Manual
IRB 2400
Please Click the Picture to continue
ABB Flexible Automation
The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
This document and parts thereof must not be reproduced or copied without
ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.
© ABB Robotics Products AB
Article number: 3HAC 2914-1
Issue: M98
ABB Robotics Products AB
S-721 68 Västerås
Sweden
ABB Flexible Automation AB
Product Manual IRB 2400 M98, On-line Manual
MAIN MENU
Introduction
Product Specification IRB 2400
Product Specification RobotWare
Safety
CE-declaration
Configuration List
System Description
Installation and Commissioning
Maintenance
Troubleshooting Tools
Fault tracing guide
Circuit Diagram
Repairs
Spare parts
Description
20 Product Specification IRB 1400 M97A/BaseWare OS 3.0
Introduction
CONTENTS
Page
2 What you must know before you use the Robot ................................................... 3
Product Manual 1
Introduction
2 Product Manual
Introduction
Introduction
1 How to use this Manual
This manual provides information on installation, preventive maintenance, troubleshooting and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation.
Anyone reading this manual should also have access to the User’s Guide.
The chapter entitled System Description provides general information on the robot structure, such as its computer system, input and output signals, etc.
How to assemble the robot and install all signals, etc., is described in the chapter on
Installation and Commissioning.
If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults.
Servicing and maintenance routines are described in the chapter on Maintenance.
2 What you must know before you use the Robot
• Normal maintenance and repair work usually only require standard tools. Some repairs, however, require specific tools. These repairs, and the type of tool required, are described in more detail in the chapter Repairs.
• The power supply must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orangecoloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller.
• Circuit boards - printed boards and components - must never be handled without
Electro-Static-Discharge (ESD) protection in order not to damage them. Use the carry band located on the inside of the controller door.
All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone.
Product Manual 3
Introduction
3 Identification
Identification plates indicating the type of robot and serial number, etc., are located on
the manipulator (see Figure 1) and on the front of the controller (see Figure 2).
The BaseWare O.S diskettes are also marked with serial number (see Figure 3).
Note! The identification plates and label shown in the figures below, only serves as examples. For exact identification see plates on your robot in question.
ABB Robotics Products AB
S-721 68 Västerås Sweden Made in Sweden
Type:
Robot version:
Man. order:
Nom. load
IRB 6400 M98
IRB 6400/2.4-150
XXXXXX
See instructions
Serial. No:
Date of manufacturing:
Net weight
2,4.120 : 1870 kg
2,4-150 : 2010 kg
2,8-120 : 2010 kg
6400-XXXX
1997-XX-XX
3.0-75 : 2010 kg
S/2,9-120 : 2240 kg
PE/2,25-75 : 1590 kg
Identification plate showing the IRB 6400
IRB 140(0) IRB 2400 IRB 4400
4
IRB 640
IRB 6400 IRB 840/A
Figure 1 Example of identification plate and it’s location on different manipulator types.
Product Manual
Introduction
.
ABB Robotics Products AB
S-721 68 Västerås Sweden Made in Sweden
Type:
Robot version:
Voltage: 3 x 400 V
Power:
Man. order:
Re.No:
Serial. No:
Date of manufacturing:
Net weight:
IRB 6400 M98
IRB 6400/2.4-150
Frequency: 50-60 Hz
7.2 kVA
XXXXXX
RXXXXXXXXXX
64-XXXXX
1998-XX-XX
240 kg
Figure 2 Identification plate on the controller.
6 4 - 0 0 0 0 0
System Key S4C 3.1
Program No 3 HAB2390-1/03
B o o t d i s k 1 (1)
Property of ABB Västerås/Sweden. All rights reserved. Reproduction, modification, use or disclosure to third parties without express authority is strictly forbidden. Copyright 1993. Restricted to be used in the controller(s) with the serial no as marked on disk.
ABB Robotics Products AB
Figure 3 Example of a label on a BaseWare O.S diskette.
Product Manual 5
Introduction
6 Product Manual
Product Specification IRB 2400
CONTENTS
Page
6 Index ................................................................................................................................. 63
Product Specification IRB 2400 M98/BaseWare OS 3.1
1
Product Specification IRB 2400
2 Product Specification IRB 2400 M98/BaseWare OS 3.1
Introduction
1 Introduction
Thank you for your interest in the IRB 2400. This manual will give you an overview of the characteristics and performance of the robot.
IRB 2400 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems.
The robot is equipped with an operating system called BaseWare OS. BaseWare OS controls every aspect of the robot, like motion control, development and execution of application programs communication etc.
The functions in this document are all included in BaseWare OS, if not otherwise specified. For additional functionality, the robot can be equipped with optional software for application support - gluing, arc welding for example, communication features - network communication - and advanced functions such as multitasking, sensor control etc. For complete information on optional software, see the Product
Specification RobotWare.
All the features are not described in this document. For a more complete and detailed description, please see the User’s Guide, RAPID Reference Manual and Product
Manual, or contact your nearest ABB Flexible Automation Centre.
Different robot versions
The IRB 2400 is available in different versions depending on its handling capacity and environment protection. The following robot versions are available, floor mounting or inverted:
Robot Versions
IRB 2400L
IRB 2400/10
IRB 2400/16
IRB 2400FL
IRB 2400F/10
IRB 2400F/16
Definition of version designation
IRB 2400 Application / Reach - Handling capacity
Version
Application
Handling capacity
Prefix Description
L Long arm
F Manipulator adapted for use in harsh environments (e.g. foundry) yy Indicates the maximum handling capacity (kg)
Product Specification IRB 2400 M98/BaseWare OS 3.1
3
Introduction
How to use this manual
The characteristics of the robot are described in Chapter 2: Description.
The most important technical data is listed in Chapter 3: Technical specification.
Note that the sections in chapter 2 and 3 are related to each other. For example, in section 2.2 you can find an overview of safety and standards, in section 3.2 you can find more detailed information.
To make sure that you have ordered a robot with the correct functionality, see
Chapter 4: Specification of Variants and Options.
In Chapter 5 you will find accessories for the robot.
Chapter 6 contains an Index, to make things easier to find.
Other manuals
The User’s Guide is a reference manual with step by step instructions on how to perform various tasks.
The programming language is described in the RAPID Reference Manual.
The Product Manual describes how to install the robot, as well as maintenance procedures and troubleshooting.
The Product Specification RobotWare describes the software options.
4 Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
2 Description
2.1 Structure
The robot is made up of two main parts: a manipulator and a controller.
Axis 4
Axis 5
Axis 6
Axis 3
Axis 2
Axis 1
Figure 1 The IRB 2400 manipulator has 6 axes.
Teach pendant
Mains switch
Operator´s panel
Disk drive
Figure 2 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.
The controller contains the electronics required to control the manipulator, external axes and peripheral equipment.
Product Specification IRB 2400 M98/BaseWare OS 3.1
5
Description
2.2 Safety/Standards
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives as well as ANSI/RIA 15.06-1992.
The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 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.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at normal program stop with no deviation from the programmed path. After approx. one second the power supplied to the motors shuts off.
6 Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
Restricting the working space
The movement of each of the axes can be restricted using software limits. Axes 1 and
2 can also be restricted by means of an adjustable mechanical stop. Axis 3 can be restricted using an electrical limit switch.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot.
When the key is released the robot will stop. The hold-to-run function makes program testing safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp. This is activated when the motors are in the MOTORS ON state.
2.3 Operation
All operations and programming can be carried out using the portable teach
pendant (see Figure 3) and the operator’s panel (see Figure 5).
Display
P1
1
2
P2
P3
7 8 9
4 5 6
1 2
0
3
Joystick
Emergency stop button
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 operation can be carried out from the teach pendant, which means that a specific keyboard is not required. All information, including the complete programming language, is in English or, if preferred, some other major language.
Product Specification IRB 2400 M98/BaseWare OS 3.1
7
Description
Menu keys
I/O list
File
Name di1 di2 grip1 grip2 clamp3B feeder progno welderror
1
Edit
1 Goto ...
View
3 Goto Bottom
Value
1
1
13
0
1
0
1
0
0
4(64)
Menu
Line indicator
Cursor
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 levels, with dedicated windows for:
- Production
- Programming
- System setup
- Service and installation
Operator’s panel
Motors On button and indicating lamp
Operating mode selector
8
Emergency stop Duty time counter
Figure 5 The operating mode is selected using the operator’s panel on the controller.
Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
Using a key switch, the robot can be locked in two or three different operating modes:
• Automatic mode:
• Manual mode at reduced speed:
Running production
Programming and setup
Max. speed: 250 mm/s (600 inches/min.)
100%
Manual mode at full speed (option):
Equipped with this mode, the robot is not approved according to ANSI/UL
Testing at full program speed
Both the operator’s panel and the teach pendant can be mounted externally, i.e. outside the cabinet. The robot can then be controlled from there.
The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals.
For more information on how to operate the robot, see the User’s Guide.
2.4 Installation
The robot has a standard configuration and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the teach pendant. The configuration can be stored on a diskette and/or transferred to other robots that have the same characteristics.
The same version of the robot can, with a simple change in the balancing system, either be mounted on the floor or inverted. An end effector, max. weight 5, 10 or 16 kg including payload, can be mounted on the robot’s mounting flange (axis 6) depending on the robot version. Other equipment can be mounted on the rear of the upper arm, max. weight 11 or 12 kg, and on the base, max. weight 35 kg.
2.5 Programming
Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”.
The programming environment can be easily customised 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 the program.
The program is stored as a normal PC text file, which means that it can be edited using a standard PC.
Product Specification IRB 2400 M98/BaseWare OS 3.1
9
Description
Movements
A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move.
The positions of a motion instruction are 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 6) 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 6 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 a rotation of an external axis)
Program management
For convenience, the programs can be named and stored in different directories.
Areas of the robot’s program memory can also be used for program storage. This gives a very fast memory where you can store programs. These can then be automatically downloaded using an instruction in the program. The complete program or parts of programs can be transferred to/from a diskette.
Programs can be printed on a printer connected to the robot, or transferred to a PC where they can be edited or printed.
10
Editing programs
Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, 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.
Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
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 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 one 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.
2.6 Automatic Operation
A dedicated production window with commands and information required by the operator is automatically displayed during automatic operation.
The operation procedure can be customised to suit the robot installation by means of user-defined operating dialogs.
Select program to run:
Front A Front B Front C Other SERVICE
Figure 7 The operator dialogs can be easily customised.
Product Specification IRB 2400 M98/BaseWare OS 3.1
11
Description
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 from 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 easily be restarted from where you left off. Digital outputs are also set automatically to the value before the power failure.
2.7 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 controller is enclosed, which means that the electronic circuitry is protected when operating in a normal workshop environment.
- It has a program memory “battery low” alarm.
The robot has several functions to provide efficient diagnostics and error reports:
- It performs a self-test when power on is set.
- Errors are indicated by a message displayed in plain language.
The message includes the reason for the fault and suggests recovery action.
- A board error is indicated by an LED on the faulty unit.
- 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 display of the teach pendant, stored in a file and also printed on a printer.
- There are commands and service programs in RAPID to test units and functions.
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.
12 Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
2.8 Robot Motion
IRB 2400L
3421
1702
R=
52
1
2885
560
100
1810
IRB 2400/10
IRB 2400/16
2900
1441
R=
44
8
2458
100
1550
Figure 8 Working space of IRB 2400 (dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
393
13
Description
14
Motion performance
The QuickMove TM 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.
The TrueMove TM 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.
The robot can, in a controlled way, pass through singular points, i.e. points where two axes coincide.
Coordinate systems
Tool Centre Point (TCP)
Y
Tool coordinates
Z
Z
X
Y
Z
Base coordinates
X
Z
User coordinates
Y
Z
Object coordinates
Y
X
Y
X
World coordinates
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.
Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tool’s centre point and orientation.
The user coordinate system specifies the position of a fixture or workpiece manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined.
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object.
Program execution
The robot can move in any of the following ways:
- Joint motion (all axes move individually and reach the programmed position at the same time)
- Linear motion (the TCP moves in a linear path)
- Circle motion (the TCP moves in a circular path)
Soft servo - allowing external forces to cause deviation from programmed position - can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part.
Product Specification IRB 2400 M98/BaseWare OS 3.1
15
Description
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.
2.9 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 a one-axis linear robot carrier and a rotational external axis.
A mechanical unit can be activated or deactivated to make it safe when, for example, manually changing a workpiece located on the unit. In order to reduce investment costs, any axes that do not have to be active at the same time can use the same drive unit.
Programs can be reused in other mechanical units of the same type.
2.10 Inputs and Outputs
A distributed I/O system is used, which makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet.
A number of different input and output units can be installed:
- Digital inputs and outputs
- Analog inputs and outputs
- Remote I/O for Allen-Bradley PLC
- InterBus-S Slave
- Profibus DP Slave
16 Product Specification IRB 2400 M98/BaseWare OS 3.1
Description
The inputs and outputs can be configured to suit your installation:
- Each signal and board 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
Signals can be assigned to special system functions, such as program start, so as to be able to control the robot from an external panel or PLC.
The robot can work as a PLC by monitoring and controlling I/O signals:
- I/O instructions can be executed concurrent with 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 option Multitasking, see
Product Specification RobotWare.
Manual commands 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
Signal connections consist of either connectors or screw terminals, which are located in the controller. I/O signals can also be routed to connectors on the upper arm of the robot.
2.11 Serial Communication
The robot can communicate with computers or other equipment via RS232/RS422 serial channels or via Ethernet. However this requires optional software, see the
Product Specification RobotWare.
Product Specification IRB 2400 M98/BaseWare OS 3.1
17
Description
18 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
3 Technical specification
Applies to standard and Foundry versions unless otherwise stated.
3.1 Structure
Weight: Manipulator
Controller
Volume: Controller
380 kg
240 kg
950 x 800 x 540 mm
Airborne noise level:
The sound pressure level outside < 70 dB (A) Leq (acc. to the working space Machinery directive 89/392 EEC)
50
540 800
Cabinet extension
Option 115
250
200
800
Extended cover
Option 114
950
980 *
500
Lifting points for forklift
* Castor wheels
500
Figure 10 View of the controller from the front and from above (dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
19
Technical specification
150
IRB 2400L
290
1225
870
360
1730
855
65
260
176 268 251 138
615
180
446
723
100
305
R=448
CL
600
R=76
444
R=347
A
123
389
A
R=330
Figure 11 View of the manipulator from the side, rear and above (dimensions in mm).
A - A
454
20 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
IRB 2400/10
IRB 2400/16
180
1065
755
135
1564
705
85
306
133
176 268 251 138
615
180
446
723
100
305 600
R=98
R=448
A - A
R=347
444
85
78
(163)
A
A
389
R=330
Figure 12 View of the manipulator from the side, rear and above (dimensions in mm).
454
Product Specification IRB 2400 M98/BaseWare OS 3.1
21
Technical specification
3.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1 Safety of machinery, terminology
EN 292-2
EN 954-1
EN 60204
Safety of machinery, technical specifications
Safety of machinery, safety related parts of control systems
Electrical equipment of industrial machines
IEC 204-1
ISO 10218, EN 775
ANSI/RIA 15.06/1992
ISO 9787
Electrical equipment of industrial machines
Manipulating industrial robots, safety
Industrial robots, safety requirements
Manipulating industrial robots, coordinate systems and motions
Degrees of protection provided by enclosures IEC 529
EN 50081-2
EN 50082-2
EMC, Generic emission
EMC, Generic immunity
ISO 9409-1 Manipulating industrial robots, mechanical interfaces
ANSI/UL 1740-1996 (option) Safety Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 424-94 (option) Industrial Robots and Robot Systems - General Safety
Requirements
Safeguarded space stops via inputs
External safety equipment can be connected to the robot’s two-channel emergency stop
chain in several different ways (see Figure 13).
Operating mode selector
Auto mode safeguarded space stop
250 mm/s
100%
General mode safeguarded space stop
External emergency stop
Emergency stop
M
~
Teach pendant
Enabling device
Note. Manual mode 100% is an option
Figure 13 All safeguarded space stops force the robot’s motors to the MOTORS OFF state.
A time delay can be connected to any safeguarded space stop.
22 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
3.3 Operation
Hold-to-run
Window keys
Display
Menu keys
P1
Motion keys
1
2
P2
P3
7 8 9
4 5 6
1 2
0
3
Function keys Navigation keys
P5
P4
Joystick
Enabling device
Figure 14 The teach pendant is very easy to use since any functions provided via the function and menu keys are described in plain language. The remaining keys can perform only one function each.
Display
16 text lines with 40 characters per line.
Motion keys
Select the type of movement for robot or external axis when jogging: linear movement, reorientation or axis-by-axis movement.
Navigation keys
Move the cursor and enter data.
Menu keys
Display pull-down menus.
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:
- Jogging (manual operation)
- Programming, editing and testing a program
- Manual input/output management
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
Product Specification IRB 2400 M98/BaseWare OS 3.1
23
Technical specification
User-defined keys
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 (see chapter 3.10).
3.4 Installation
Operating requirements
Protection standards
Normal Manipulator
Wrist
Controller
IEC529
IP54
IP54
IP54
IRB 2400F Manipulator
Wrist
Controller
IP55
IP67
IP54
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
Controller during operation
+5 o
C (41 o
+5 o
C (41 o
F) to +45 o
C (113 o
F) to +52 o
C (125 o
F)
F)
Complete robot during transportation and storage -25 o
C (13 o
F) to +55 o
C (131 o
F)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation Max. 95% at constant temperature
Power supply
Mains voltage 200-600V, 3p (3p + N for certain options), +10%,-15%
48.5 to 61.8 Hz Mains frequency
Rated power (transformer size):
Absolute measurement backup
4.5-14.4 kVA
1000 h (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
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
24 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Language
Date and time
Power on sequence
EM stop sequence
Main start sequence
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 Program start sequence
Program stop sequence Action taken at program stop
Change program sequence Action taken when a new program is loaded
Working space
External axes
Brake delay time
I/O signal
Working space limitations
Number, type, common drive unit, mechanical units
Time before brakes are engaged
Logical names of boards and signals, I/O mapping,
Serial communication 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.
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load in operation
IRB 2400L Force xy ±1700 N
Force z floor mounting +4100 ±1100 N
Force z inverted mounting 4100 ±1100 N
IRB 2400/10
IRB 2400/16
Torque xy
Torque z
±3000 Nm
±450 Nm
Force xy
Force z floor mounting
±2000 N
+4100 ±1400 N
Force z inverted mounting 4100 ±1400 N
Torque xy
Torque z
±3400 Nm
±550 Nm
Max. load at emergency stop
±2100 N
+4100 ±1400 N
4100 ±1400 N
±3400 Nm
±900 Nm
±2600 N
+4100 ±1900 N
4100 ±1900 N
±4000 Nm
±900 Nm
Product Specification IRB 2400 M98/BaseWare OS 3.1
25
Technical specification
X
B
Z = centre line axis 1 48
B
Y
B - B
D=18,5
0.5
Z
A
D=18,5 (2x)
A
The same dimensions
48
20
260 260
0.25
View from the bottom of the base
Figure 15 Hole configuration (dimensions in mm).
A - A
D=35
+0.039
-0 H8 (2x)
26 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Load diagrams
Z (mm)
600
IRB 2400L
500
400
300
200
100
3 kg
4 kg
5 kg
2 kg
1.5 kg
1 kg
Nominal performance
65
100 200 300 400
L (mm)
Z = see the above diagram and the coordinate system in Figure 9
L = distance in X-Y plane from Z-axis to the centre of gravity
J = maximum own moment of inertia on the total handling weight =
≤
0.012 kgm 2
Figure 16 Maximum weight permitted for load mounting on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 2400 M98/BaseWare OS 3.1
27
Technical specification
Z (mm)
600
IRB 2400L
Reduced performance
1 kg
500
65
400
300
200
100
4 kg
5 kg
6 kg
7 kg
3 kg
2 kg
1.5 kg
100 200 300 400
L (mm)
28
Z = see the above diagram and the coordinate system in Figure 9
L = distance in X-Y plane from Z-axis to the centre of gravity
J = maximum own moment of inertia on the total handling weight =
≤
0.012 kgm 2
Figure 17 Maximum weight permitted for load mounting on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
85
200
150
100
50
Z (mm)
IRB 2400/10
10 kg
12 kg
8 kg
6 kg
100 150 200
L (mm)
Z = see the above diagram and the coordinate system in Figure 9
L = distance in X-Y plane from Z-axis to the centre of gravity
J = maximum own moment of inertia on the total handling weight =
≤
0.040 kgm 2
Figure 18 Maximum weight permitted for load mounting on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 2400 M98/BaseWare OS 3.1
29
Technical specification
85
IRB 2400/16
200
150
100
50
Z (mm)
14 kg
16 kg
12 kg
10 kg
100 150 200
L (mm)
30
Z = see the above diagram and the coordinate system in Figure 9
L = distance in X-Y plane from Z-axis to the centre of gravity
J = maximum own moment of inertia on the total handling weight =
≤
0.060 kgm 2
Figure 19 Maximum weight permitted for load mounting on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Mounting equipment
The robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment.
IRB 2400L
300
A
A
Max. 10kg
M8 (2x)
Depth 14
Max. 1kg
135 150
D=200 30
170
400
A - A
470
CL
M8 (3x) R=77
Depth 16
C
120 o (3x)
B 150
D=50 M8 (3x) R=92
Depth 16
38 o
120 o (3x)
B
C - C Max. 35 kg total
C
38 o
B - B
Figure 20 The shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
31
Technical specification
IRB 2400/10
IRB 2400/16
A
110
300
A
M6 (2x) M8 (3x)
Depth of thread 14
65 177
32
M5 (2x)
300 450
100
D=240 22
78
43 Max. 2kg
90
A - A Max. 10kg
200
M8 (3x) R=77
Depth 16
C
120 o (3x)
B 150
D=50 M8 (3x) R=92
Depth 16
38 o
120 o (3x)
B
C - C Max. 35 kg total
C
38 o
B - B
Figure 21 The shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
R=20
45 o
A
IRB 2400L
+0.012
D=6 H7
∅
0.05
B
M6 (4x)
A
90 o (4x)
9
B
+0.027 -0
+0 -0.039
6
A - A
6 o
0
5 x
A
30 o
IRB 2400/10
IRB 2400/16
D=6
+0.012
-0
H7, depth min 8
0.05 B
10
M6 (6x)
R=25
+0.039 -0
+0 -
B
A
7
A - A
Figure 22 The mechanical interface, mounting flange (dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
33
Technical specification
34
3.5 Programming
The programming language RAPID is a high-level application-oriented programming language and includes the following functionality:
- hierarchial and modular structure
- functions and procedures
- global or local data and routines.
- data typing, including structured and array types
- user defined names on variables, routines, inputs/outputs etc.
- extensive program flow control
- arithmetic and logical expressions
- interrupt handling
- error handling
- user defined instructions
- backward execution handler
The available sets of instructions/functions are given below. A subset of instructions to suit the needs of a particular installation, or the experience of the programmer, can be installed in pick lists. New instructions can easily be made by defining macros consisting of a sequence of standard instructions.
Note that the list below only cover BaseWare OS. For instructions and functions associated with optional software, see Product Specification RobotWare.
Miscellaneous
:=
WaitTime
WaitUntil comment
OpMode
RunMode
Dim
Present
Load
UnLoad
Assigns a value
Waits a given amount of time
Waits until a condition is met
Inserts comments into the program
Reads the current operating mode
Reads the current program execution mode
Gets the size of an array
Tests if an optional parameter is used
Loads a program module during execution
Deletes a program module during execution
To control the program flow
ProcCall
CallByVar
Calls a new procedure
Calls a procedure by a variable
RETURN
FOR
GOTO
Compact IF
Finishes execution of a routine
Repeats a given number of times
Goes to (jumps to) a new instruction
If a condition is met, then execute one instruction
IF label
TEST
If a condition is met, then execute a sequence of instructions
Line name (used together with GOTO)
Depending on the value of an expression ...
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
WHILE
Stop
EXIT
Break
Repeats as long as ...
Stops execution
Stops execution when a restart is not allowed
Stops execution temporarily
Motion
MoveC
MoveJ
MoveL
MoveAbsJ
MoveXDO
SearchC
SearchL
ActUnit
DeactUnit
Offs
RelTool
MirPos
CRobT
CJointT
CPos
CTool
CWObj
StopMove
StartMove
Motion settings
AccSet
ConfJ
ConfL
VelSet
GripLoad
SingArea
PDispOn
PDispSet
DefFrame
DefDFrame
EOffsOn
EOffsSet
ORobT
SoftAct
TuneServo
Reduces the acceleration
Controls the robot configuration during joint movement
Monitors the robot configuration during linear movement
Changes the programmed velocity
Defines the payload
Defines the interpolation method through singular points
Activates program displacement
Activates program displacement by specifying a value
Defines a program displacement automatically
Defines a displacement frame
Activates an offset for an external axis
Activates an offset for an external axis using a value
Removes a program displacement from a position
Activates soft servo for a robot axis
Tunes the servo
Moves the TCP circularly
Moves the robot by joint movement
Moves the TCP linearly
Moves the robot to an absolute joint position
Moves the robot and set an output in the end position
Searches during circular movement
Searches during linear movement
Activates an external mechanical unit
Deactivates an external mechanical unit
Displaces a position
Displaces a position expressed in the tool coordinate system
Mirrors a position
Reads current robot position (the complete robtarget)
Reads the current joint angles
Reads the current position (pos data)
Reads the current tool data
Reads the current work object data
Stops robot motion
Restarts robot motion
Input and output signals
InvertDO
PulseDO
Reset
Inverts the value of a digital output signal
Generates a pulse on a digital output signal
Sets a digital output signal to 0
Set
SetAO
SetDO
Sets a digital output signal to 1
Sets the value of an analog output signal
Sets the value of a digital output signal after a defined time
SetGO
WaitDI
WaitDO
AInput
DInput
Sets the value of a group of digital output signals
Waits until a digital input is set
Waits until a digital output is set
Reads the value of an analog input signal
Reads the value of a digital input signal
Product Specification IRB 2400 M98/BaseWare OS 3.1
35
Technical specification
36
DOutput
GInput
GOutput
TestDI
IODisable
IOEnable
Interrupts
ISignalDI
ISignalDO
ITimer
IDelete
ISleep
IWatch
IDisable
IEnable
CONNECT
Error Recovery
EXIT
RAISE
RETRY
TRYNEXT
RETURN
Communication
TPErase
TPWrite
TPReadFK
TPReadNum
ErrWrite
System & Time
ClkReset
ClkStart
ClkStop
ClkRead
CDate
CTime
GetTime
Mathematics
Add
Clear
Decr
Incr
Abs
Sqrt
Exp
Pow
ACos
ASin
ATan/ATan2
Cos
Sin
Reads the value of a digital output signal
Reads the value of a group of digital input signals
Reads the value of a group of digital output signals
Tests if a digital input signal is set
Disables an I/O module
Enables an I/O module
Orders interrupts from a digital input signal
Orders interrupts from a digital output signal
Orders a timed interrupt
Cancels an interrupt
Deactivates an interrupt
Activates an interrupt
Disables interrupts
Enables interrupts
Connects an interrupt to a trap routine
Terminates program execution
Calls an error handler
Restarts following an error
Skips the instruction that has caused the error
Returns to the routine that called the current routine
Erases text printed on the teach pendant
Writes on the teach pendant
Reads function keys
Reads a number from the teach pendant
Stores an error message in the error log
Resets a clock used for timing
Starts a clock used for timing
Stops a clock used for timing
Reads a clock used for timing
Reads the current date as a string
Reads the current time as a string
Gets the current time as a numeric value
Adds a numeric value
Clears the value
Decrements by 1
Increments by 1
Calculates the absolute value
Calculates the square root
Calculates the exponential value with the base “e”
Calculates the exponential value with an arbitrary base
Calculates the arc cosine value
Calculates the arc sine value
Calculates the arc tangent value
Calculates the cosine value
Calculates the sine value
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Tan
EulerZYX
OrientZYX
PoseInv
PoseMult
PoseVect
Round
Trunc
Calculates the tangent value
Calculates Euler angles from an orientation
Calculates the orientation from Euler angles
Inverts a pose
Multiplies a pose
Multiplies a pose and a vector
Rounds a numeric value
Truncates a numeric value
Text strings
NumToStr
StrFind
StrLen
StrMap
StrMatch
StrMemb
StrOrder
StrPart
StrToVal
ValToStr
Converts numeric value to string
Searches for a character in a string
Gets the string length
Maps a string
Searches for a pattern in a string
Checks if a character is a member of a set
Checks if strings are ordered
Gets a part of a string
Converts a string to a numeric value
Converts a value to a string
For more information on the programming language, see RAPID Reference Manual.
Memory
Memory size
Program memory:
Standard
Extended memory 8 MB
2.5 MB 2)
6.0 MB 2)
Mass storage 3) :
RAM memory Standard 0.5 MB
Extended 8 MB 4.0 MB
Instructions
7500
18000
3000
31000
1)
Diskette 1.44 MB 15000
1) Depending on type of instruction.
2) Some software options reduce the program memory. See Product
Specification RobotWare.
3) Requires approx. 3 times less space than in the program memory, i.e. 1 MB mass memory can store 3 MB of RAPID instructions.
Type of diskette: 3.5” 1.44 MB (HD) MS DOS format.
Programs and all user-defined data are stored in ASCII format.
Memory backup
The RAM memory is backed up by two Lithium batteries. Each battery has a capacity of 5-6 months power off time (depending of memory board size).
A warning is given at power on when one of the batteries is empty.
Product Specification IRB 2400 M98/BaseWare OS 3.1
37
Technical specification
3.6 Automatic Operation
The following production window commands are available:
- Load/select the program
- Start the program
- Execute instruction-by-instruction (forward/backward)
- Reduce the velocity temporarily
- Display program-controlled comments (which tell the operator what is happening)
- Displace a position, also during program execution (can be blocked)
3.7 Maintenance and Troubleshooting
The following maintenance is required:
- Changing filter for the transformer/drive unit cooling every year.
- Charging gas in the balancing spring every third year.
- Changing batteries every third year.
The maintenance intervals depends on the use of the robot. For detailed information on maintenance procedures, see Maintenance section in the Product Manual.
38 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
3.8 Robot Motion
IRB 2400L
The working area is the same for both floor and inverted mounting
Type of motion Range of movement
Axis 1 Rotation motion +180 o
to -180 o
Axis 2 Arm motion +110 o to -100 o
Axis 3 Arm motion
Axis 4 Wrist motion
+65 o
+185 o to -60 to -185 o o
Axis 5 Bend motion
Axis 6 Turn motion
+115 o
+400 o to -115 o to -400 o
(Unlimited as optional)
3421
Z
Pos 1
Wrist centre
Pos 0
Axis 4
Axis 3
1702
+
+
Axis 5
+ +
Axis 6
Pos 6
Axis 2 +
R=
521
Pos 2
2885
Pos 5
X
Axis 1
100
Pos 4
Pos 3
560
R=5
70
R
=4
00
Pos 4
1810
Positions at wrist centre (mm) pos.
x z
4
5
6
2
3
0
1
970
404
602
1577
400
-1611
-115
1620
2298
745
-246
-403
623
1088
Figure 23 The extreme positions of the robot arm (dimensions in mm).
Angle (degrees) pos.
axis 2 axis 3
4
5
6
2
3
0
1
0
110
0
0
110
-100
-100
0
-60
65
-60
24.5
-60
65
Product Specification IRB 2400 M98/BaseWare OS 3.1
39
Technical specification
IRB 2400/10, IRB 2400/16
The working area is the same for both floor and inverted mounting
Type of motion Range of movement
Axis 1 Rotation motion +180
Axis 2 Arm motion +110 o o
to -180 to -100 o o
Axis 3 Arm motion
Axis 4 Wrist motion
+65 o
+200 o to -60 o to -200 o
(Unlimited as optional)
Axis 5 Bend motion
Axis 6 Turn motion
+120
+400 o o to -120 o to -400 o
(Unlimited as optional)
2900
Z
Pos 1
Axis 4
Wrist centre
Pos 0
Axis 3
1441
Pos 5
Axis 2
Pos 6
+
+
Axis 5
+ +
Axis 6
+
R=
448
Pos 2
2458
X
Axis 1
100
Pos 4
Pos 3
393
R=5
70
1550
R
=4
00
Pos 4
Positions at wrist centre (mm) pos.
x z
4
5
6
2
3
0
1
855
360
541
1351
400
-1350
-53
1455
2041
693
-118
-302
624
1036
Angle (degrees) pos.
axis 2 axis 3
4
5
6
2
3
0
1
0
110
0
0
110
-100
-100
0
-60
65
-60
18.3
-60
65
Figure 24 The extreme positions of the robot arm (dimensions in mm).
40 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Performance according to ISO 9283
At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axes in motion.
Unidirectional pose repeatability:
RP = 0.06 mm
Linear path accuracy:
AT = 0.45 - 1.0 mm
Linear path repeatability:
RT = 0.14 - 0.25 mm
Minimum positioning time, to within 0.2 mm of the position:
0.2 - 0.35 sec. (on 35 mm linear path)
0.4 - 0.6 sec. (on 350 mm linear path)
The above values are the range of average test-results from a number of robots. If guaranteed values are required, please contact your nearest ABB Flexible Automation
Centre.
Velocity
Versions:
Axis no. 1
2
3
4
5
6
IRB 2400L IRB 2400/10 IRB 2400/16
150 o /s
150 o /s
150 o /s
360 o /s
360 o /s
450 o /s
150
150 o
150 o
360
360 o
450 o o o
/s
/s
/s
/s
/s
/s
150
150 o
150 o
360
360 o
450 o o o
/s
/s
/s
/s
/s
/s
There is a supervision to prevent overheating in applications with intensive and frequent movements.
Resolution
Approx. 0.01
o on each axis.
Product Specification IRB 2400 M98/BaseWare OS 3.1
41
Technical specification
3.9 External Axes
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 25, or inside the cabinet.
For more information on how to install an external axis, see the Product Manual -
Installation and Commissioning.
When more than two external axes are used, the drive units for external axis 3 and
upwards must be placed in a separate cabinet according to Figure 25.
Not supplied on delivery
Alt.
SMB
42
Optional
SMB
Not supplied on delivery
Figure 25 Outline diagram, external axes.
Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
3.10 Inputs and Outputs
Types of connection
The following types of connection are available:
- “Screw terminals” on the I/O units
- Serial interface for distributed I/O units
- Air and signal connections to upper arm
For more detailed information, see Chapter 4: Specification of Variants and Options.
I/O units
Several I/O units can be used. The following table shows the maximum number of physical signals that can be used on each unit.
Type of unit
Digital I/O 24 VDC
Digital I/O 120 VAC
Analog I/O
AD Combi I/O
Relay I/O
Allen-Bradley
Remote I/O Slave
Interbus-S Slave
Profibus DP Slave
Simulated I/O
3
Option no.
20x
25x
22x
23x
26x
281
284-285
286-287
Digital
In Out Voltage inputs
16
16
16
16
128
2
16
16
16
16
128
64
2
128
2
64
128
100 100
4
Analog
Voltage output
3
2
Current output
1
Power supply
Internal/External
Internal/External
Internal
30 30
Encoder interface unit
4
288-289 1
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for RIO unit and 1 for Interbus-S and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
1
Internal/External
1
Internal/External
1
Distributed I/O
The total number of logical signals is 512 (inputs or outputs, group I/O, analog and digital including field buses)
Max. total no of units*
Max. total cable length
20 (including SIM units)
100 m
Cable type (not included) According to DeviceNet specification release 1.2
Data rate (fixed) 500 Kbit/s
* Max. four units can be mounted inside the cabinet.
Product Specification IRB 2400 M98/BaseWare OS 3.1
43
Technical specification
Signal data
Permitted customer 24 V DC load max. 6 A
Digital inputs (options 20x/23x/26x)
24 V DC Optically-isolated
Rated voltage:
Logical voltage levels: “1”
“0”
Input current at rated input voltage:
Potential difference:
Time delays: hardware software
Time variations:
24 V DC
15 to 35 V
-35 to 5 V
6 mA max. 500 V
5−15
ms
≤ 3 ms
± 2 ms
Digital outputs (options 20x/23x)
24 V DC Optically-isolated, short-circuit protected, supply polarity protection
Voltage supply 19 to 35 V
Rated voltage
Output current:
Potential difference:
Time delays: hardware
Time variations: software
24 V DC max. 0.5 A max. 500 V
≤ 1 ms
≤ 2 ms
± 2 ms
Relay outputs (options 26x)
Single pole relays with one male contact (normally open)
Rated voltage:
Voltage range:
24 V DC, 120 VAC
19 to 35 V DC
Output current:
24 to 140 V AC max.
2 A
Potential difference: max.
500V
Time intervals: hardware (set signal) typical 13 ms hardware (reset signal) typical 8 ms software
≤ 4 ms
Digital inputs
120 V AC (options 25x)
Optically isolated
Rated voltage
Input voltage range: “1”
Input voltage range: “0”
Input current (typical):
Time intervals: hardware software
120 V AC
90 to 140 V AC
0 to 45 V AC
7.5 mA
≤ 20 ms
≤ 4 ms
44 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
Digital outputs
120 V AC (options 25x)
Optically isolated, voltage spike protection
Rated voltage 120 V AC
Output current: max.
1A/channel, 12 A
16 channels or max.
2A/channel, 10 A
16 channels
(56 A in 20 ms) min.
30mA
Voltage range:
Potential difference:
Off state leakage current:
On state voltage drop:
Time intervals: hardware software
24 to 140 V AC max.
500 V max. 2mA rms max. 1.5 V
≤
12 ms
≤ 4 ms
Analog inputs (options 22x)
Voltage Input voltage:
Input impedance:
Resolution:
Accuracy:
+10 V
>1 Mohm
0.61 mV (14 bits)
+0.2% of input signal
Analog outputs (option 22x)
Voltage Output voltage:
Load impedance:
Resolution:
Current Output current:
Load impedance:
Resolution:
Accuracy:
+10 V min.
2 kohm
2.44 mV (12 bits)
4-20 mA min.
800 ohm
4.88
µ
A (12 bits)
+0.2% of output signal
Analog outputs (option 23x)
Output voltage (galvanically isolated): 0 to +10 V
Load impedance: min.
2 kohm
Resolution:
Accuracy:
Potential difference:
Time intervals: hardware software:
2.44 mV (12 bits)
±25 mV ±0.5% of output voltage max. 500 V
≤
2.0 ms
≤ 4 ms
Signal connections on robot arm
For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling, one Burndy UTG 014 12SHT connector and one Burndy
UTG 018 23SHT connector on the rear part of the upper arm.
A hose for compressed air is also integrated into the manipulator. There is an inlet
(R1/4”) at the base and an outlet (R1/4”) on the rear part of the upper arm.
Signals
Power
Air
23
10
1
50 V, 250 mA
250 V, 2 A
Max. 8 bar, inner hose diameter 8 mm
Product Specification IRB 2400 M98/BaseWare OS 3.1
45
Technical specification
System signals
Signals can be assigned to special system functions. Several signals can be given the same functionality.
Digital outputs
Digital inputs
Analog output
Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Run chain closed
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 program 1
Loads and starts program from the beginning 1
Resets error
Resets emergency stop
System reset
Synchronizes external axes
TCP speed signal
1. Program can be decided when configuring the robot.
For more information on system signals, see User’s Guide - System Parameters.
46 Product Specification IRB 2400 M98/BaseWare OS 3.1
Technical specification
3.11 Communication
The robot has two serial channels one RS232 and one RS422 Full duplex which can be used to communicate point to point with printers, terminals, computers and
other equipment (see Figure 26).
Figure 26 Serial point-to-point communication.
The serial channels can be used at speeds of 300 to 19200 bit/s (max. 1 channel with speed 19200 bit/s).
For high speed and/or network communication, the robot can be equipped with
Ethernet interface (see Figure 27). Transmission rate is 10Mbit/s.
Figure 27 Serial network communication.
Character-based or binary information can be transferred using RAPID instructions.
This requires the option Advanced functions, see Product Specification RobotWare.
In addition to the physical channels, a Robot Application Protocol (RAP) can be used.
This requires either the option FactoryWare Interface or RAP Communication, see
Product Specification RobotWare.
Product Specification IRB 2400 M98/BaseWare OS 3.1
47
Technical specification
48 Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
4 Specification of Variants and Options
The different variants and options for the IRB 2400 are described below.
The same numbers are used here as in the Specification form.
For software options, see Product Specification RobotWare.
Note Options marked with * are inconsistent with UL/UR approval.
020 ROBOT VERSIONS
021 IRB 2400L
022 IRB 2400FL
023 IRB 2400/10
024 IRB 2400F/10
025 IRB 2400/16
026 IRB 2400F/16
IRB 2400 Application / Reach - Handling capacity
Application:
Reach:
Handling capacity:
F Robot adapted for foundry environments.
Degree of protection as in chapter 3.4.
The manipulator is finished with a special coating.
Specifies the max. reach at the wrist centre.
Specifies the nominal handling capacity.
020 MOUNTING POSITION
This choice specifies the configuration the robot will be delivered in. It can easily be changed without additional parts.
02x Floor mounted
02y Hanging
040 APPLICATION INTERFACE
For more details see chapter 3.10.
041 Integrated hose and cables for connection of extra equipment on the manipulator to the rear end of the upper arm.
043 Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. Not possible on IRB 2400L, option 021 and 022.
045 The signals are connected directly to the robot base to one 40-pins Harting connector.
Product Specification IRB 2400 M98/BaseWare OS 3.1
49
Specification of Variants and Options
67x The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08,
to the controller. See Figure 34.
If 43x
If 043
If 67x
070 POSITION SWITCH AXIS 1
Switches indicating the position of axis 1.
A design with two stationary switches is available. The switches are manufactured by
Telemecanique and of type forced disconnect.
Note The switches are not recommended to be used in severe environment with sand or chips.
07x The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the controller.
081 One switch, axis 1(see Figure 28)
082 Two switches, axis 1 (see Figure 28)
083 Three switches, axis 1 (see Figure 28)
The first switch
Controller
The second switch
Controller
The third switch
Controller
Figure 28 Connections of the switches
084 Two switches, axis 1, stationary (see Figure 29)
The two switches divide the working area of axis 1 into two fixed working zones, approx. 175 o each. Together with external safety arrangement, this option allows access to one working zone at the same time as the robot is working in the other one.
Controller
Figure 29 Connections of the switches.
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.
110 CABINET SIZE
111 Standard cabinet (with upper cover).
112 Standard cabinet without upper cover. To be used when cabinet extension is mounted on top of the cabinet after delivery.
50 Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
114 With extended cover 250 mm.
The height of the cover is 250 mm, which increases the available space for external equipment that can be mounted inside the cabinet.
115 With cabinet extension, 800 mm.
A cabinet extension is mounted on top of the standard cabinet. There is a mounting plate
The cabinet extension is opened via a front door and it has no floor. The upper part of the standard cabinet is therefore accessible.
This option cannot be combined with option 142.
Shaded area 40x40
(four corners) not available for mounting
705
730
Figure 30 Mounting plate for mounting of equipment (dimensions in mm).
120 CABINET TYPE
121 Standard, i.e. without Castor wheels.
122 Cabinet on Castor wheels.
125 ARCITEC
A special designed cabinet dedicated for SEFAW arc welding system ARCITEC
Requires option 111 or 114 + 131, 145 or 146 and 147 or 149.
130 CONNECTION OF MAINS
The power is connected either inside the cabinet or to a connector on the cabinet’s lefthand side. The cable is not supplied. If option 133-136 is chosen, the female connector
(cable part) is included.
131 Cable gland for inside connection. Diameter of cable: 11-12 mm.
133* 32 A, 380-415 V, 3p + PE (see Figure 31).
Product Specification IRB 2400 M98/BaseWare OS 3.1
Figure 31 CEE male connector.
51
Specification of Variants and Options
134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640.
35 A, 600 V, 6p + PE (see Figure 32).
136* 32 A, 380-415 V, 3p + N + PE (see Figure 31).
Figure 32 DIN male connector.
140 MAINS SWITCH
141*/145* Rotary switch in accordance with the standard in section 3.2 and IEC 337-1,
VDE 0113.
142/146 Rotary switch according to 141 with door interlock.
143 Flange disconnect in accordance with the standard in section 3.2. Includes door interlock.
Additions to the mains switch:
147/149 Circuit breaker for rotary switch. A 16 A (transformer 2 and 3) or 25 A (transformer 1) circuit breaker for short circuit protection of main cables in the cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660.
150 MAINS VOLTAGE
The robot can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible in each connection.
Voltage Voltage 151-174 Voltage
200 V
220 V
400 V
440 V
400 V
440 V
475 V
500 V
475 V
500 V
525 V
600 V
175 MAINS FILTER
The mains filter reduces the emission of radio frequency on the incoming power, to levels below requirements in the Machinery Directive 89/392/EEC. For installations in countries not affected by this directive, the filter can be excluded.
177/179 Mains filter
52 Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
180 OPERATOR’S PANEL
The operator’s panel and teach pendant holder can be installed either
181 Standard, i.e. on the front of the cabinet, or
182 External, i.e. in a separate operator’s unit.
All necessary cabling, including flange, connectors, sealing strips, screws, etc., is supplied.
External enclosure is not supplied.
45 o
196
70
M4 (x4)
M8 (x4)
193 223
Required depth 200 mm
62
96
Holes for flange
External panel enclosure
(not supplied)
140
184
200
Holes for operator’s panel
180 224 240
Teach pendant connection
Connection to the controller
5 (x2)
Holes for teach pendant holder
90
155
Figure 33 Required preparation of external panel enclosure (all dimensions in mm).
Product Specification IRB 2400 M98/BaseWare OS 3.1
53
Specification of Variants and Options
183 External, mounted in a box,
(see figure on the right).
Cable length
185 15 m
186 22 m
187 30 m
M5 (x4) for fastening of box
337
Connection flange
370
190 OPERATING MODE SELECTOR
193 Standard, 2 modes: manual and automatic
191* Standard, 3 modes: manual, manual full speed and automatic.
This option is inconsistent with UL/UR approval.
200 I/O MODULES MOUNTED IN CABINET
The standard cabinet can be equipped with up to four I/O units. For more details, see Technical
Specification 3.10.
I/O units (x4)
X1 (SIO1)
X2 (SIO2)
X10 (CAN3)
X16 (CAN2)
Backplane
54
XT5, customer signals
XT6, customer power
XT8, position switch
XT31 (24V supply) and service outlet
Figure 34 I/O unit and screw terminal locations.
Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
20x Digital 24 VDC I/O: 16 inputs/16 outputs.
22x Analog I/O: 4 inputs/4 outputs.
23x AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
25x Digital 120 VAC I/O 16 inputs/16 outputs.
26x 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
The signals are connected directly to the I/O units in the upper part of the cabinet (see Figure
34). Connectors Phoenix MSTB 2.5/xx-ST-5.08 (MC 1.5/xx-ST-3.81 for option 22x) or
equivalent are included:
Option 20x: four 10 pole connectors
Option 22x: two 16 pole and two 12-pole connectors
Option 25x, 26x: four 16 pole connectors
Option 23x: four 10 pole and one 6 pole connector.
280 FIELD BUSES
For more details, see Technical Specification 3.10.
281 Allen-Bradley Remote I/O Slave
Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC equipped with an Allen-Bradley 1771 RIO node adapter. The unit reduces the number of
I/O units that can be mounted in cabinet by one. The field bus cables are connected directly
to the A-B RIO unit in the upper part of the cabinet (see Figure 34). Connectors Phoenix
MSTB 2.5/xx-ST-5.08 or equivalent are included.
284 InterBus-S Slave
Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC equipped with an InterBus-S interface. The unit reduces the number of I/O units that can be mounted in cabinet by one or two. The signals are connected directly to the
InterBus-S-slave unit (two 9-pole D-sub) in the upper part of the cabinet.
286 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 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.
288 Encoder interface unit for conveyor tracking
Conveyor Tracking, or Line Tracking, is a function which allows the robot to follow a work object mounted on a moving conveyor. The encoder and synchronization switch cables are connected directly to the encoder interface unit in the upper part of the cabinet
(see Figure 34). A screw connector is included. For more information see Product
Specification RobotWare.
Product Specification IRB 2400 M98/BaseWare OS 3.1
55
Specification of Variants and Options
290 COMMUNICATION
As standard, the robot is equipped with one RS232 (SIO 1) and one RS422 (SIO 2) connector inside the cabinet. The connectors to be used (Phoenix MSTB 2.5/12-ST-5.08) are not included.
292 Ethernet (see Figure 27). Connectors: RJ45 and AUI on the board front.
294 Distributed I/O (CAN-bus) connection on the left wall.
390 EXTERNAL AXES DRIVES - INSIDE CABINET
The controller is equipped 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.)
The transformer 4.5 kVA is replaced with 7.2 kVA.
391 Drive unit T
The drive unit is part of the DC-link. Recommended motor type see Figure 35.
392 Drive unit GT
A separate drive unit including two drives. Recommended motor types see Figure 35.
394 Drive unit T+GT
A combination of 391 and 392.
395 Drive unit C
The drive unit is part of the DC-link. Recommended motor type see Figure 35.
396 Drive unit C+GT
A combination of 395 and 392.
398 Prepared for GT
No drive units or cables are included, only transformer 7.2 kVA.
385 EXTERNAL AXES MEASUREMENT BOARD
The resolver can either be connected to a serial measurement board outside the controller, or to a measurement board inside the cabinet.
386 Serial measurement board inside cabinet
Signal interface to external axes with absolute position at power on. The board is located in the cabinet and occupies one I/O unit slot. The resolvers are connected to a standard industrial 64-pin connector in accordance with DIN 43652, on the left-hand side of the cabinet.
387 Serial measurement board as separate unit
370 EXTERNAL AXES DRIVES - SEPARATE CABINET
If more external axes than in option 390 are to be used, an external cabinet can be supplied. 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 7.2 kVA, and one mains switch are included.
37M-O
Drive unit GT, for 2,4, or 6 motors. Recommended motor types see Figure 35.
37P-Q
Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 35.
56 Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
Drive unit data Max current Rated current
T
G
E
C
7,5 - 37A rms
6 - 30A
rms
5,5 - 27A
2,5 - 11A rms rms
20A rms
8,4A rms
5A rms
B 1,5 - 7A rms
4A rms
1. Motors from Flexible Automation/System Products.
Types: S=small, M=medium, L=large
Figure 35 Motor selecting table.
Motor type
1
S, M, L
S, M, L
S, M
S
S
420 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).
421* 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for
Sweden, Germany and other countries.
422* 230 V in accordance with French standard; single socket.
423* 120 V in accordance with British standard; single socket.
424 120 V in accordance with American standard; single socket, Harvey Hubble.
425* Service outlet according to 421 and a computer connection on the front of the cabinet.
The computer connection is connected to the RS232 serial channel. Cannot be used if option 142 is chosen.
430 POWER SUPPLY TO SERVICE OUTLETS
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.
433 Connection before mains switch with an additional transformer for line voltages
400-500 V and with a secondary voltage of 115 V, 4A or 230 V, 2A.
Note! Connection before mains switch is not in compliance with some national standards, NFPL 79 for example.
Product Specification IRB 2400 M98/BaseWare OS 3.1
57
Specification of Variants and Options
439 Earth fault protection for service outlet.
To increase personal safety, the service outlet can be supplied with an earth fault protection which trips at 30 mA earth current. The earth fault protection is placed next
to the service outlet (see Figure 34). Voltage range: 110 - 240 V AC.
470 DISK DRIVE COOLING
The disk drive normally works well at temperatures up to +40 o C (104 o F). At higher temperatures a cooling device for the drive is necessary to ensure good functionality. The disk drive will not deteriorate at higher temperatures but there will be an increase in the number of reading/writing problems as the temperature increases.
471 No
472 Yes
620 KIT FOR LIMITING WORKING SPACE
To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted.
621 Axis 1
Two extra stops for restricting the working range.
The stops can be mounted within the area from 50 o to 140 o
50 o
140 o
622 Axis 2
Stop lugs for restricting the working range.
Figure 37 illustrates the mounting positions
of the stops.
80 o
50 o
50 o
Figure 36
20 o
140 o
40 o
70 o
58
Figure 37
623 Axis 3
Equipment for electrically restricting the working range in increments of 5 o .
Product Specification IRB 2400 M98/BaseWare OS 3.1
Specification of Variants and Options
630 TEACH PENDANT LIGHTING
The teach pendant is, as standard, equipped with a sharp and clear display without back lighting.
Back lighting is available as an option.The cable lenght for the teach pendant is 10 m. For extension cable, see option 660.
632 Without back lighting
631 With back lighting
640 CABLE MANIPULATOR – CONTROLLER
64x Internal connectors
The cables are connected directly to the drive units inside the cabinet via a cable gland on the left-hand side of the controller and to a connector inside the robot base.
65x External connectors
The cables are connected to Harting connectors in accordance with DIN 43652, located on the left-hand side of the controller and on the base of the manipulator.
The cables are available in the following lengths:
7 m
15 m
22 m
30 m
660 EXTENSION CABLE FOR THE TEACH PENDANT
66x 10 m
This can be connected between the controller and the connector on the teach pendant’s cable. A maximum of two extension cables may be used; i.e. the total length of cable between the controller and the teach pendant should not exceed 30 m. If external control panel (option 182 or 183) with 15 m cable is used, an extension cable is allowed, and the total cable length can be up to 35 m.
680 ADDITIONAL I/O UNITS
I/O units can be delivered separately. The units can then be mounted outside the cabinet
or in the cabinet extension. Dimensions according to Figure 38 and Figure 39. These are
connected in a chain to a connector (CAN 3 or CAN 2, see Figure 34) 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. For more details, see Technical Specification
3.10. External enclosure must provide protection class IP 54 and EMC shielding.
68ADigital I/O 24 V DC: 16 inputs/16 outputs.
68G-H Analog I/O.
68I-L AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
68M-P Digital I/O 120 V AC: 16 inputs/16 outputs.
68Q-T Digital I/O with relay outputs: 16 inputs/16 outputs.
Product Specification IRB 2400 M98/BaseWare OS 3.1
59
Specification of Variants and Options
68U Allen Bradley Remote I/O
68V-X Interbus-S Slave
68Y-Z Profibus DP Slave
69A-B Encoder unit
EN 50022 mounting rail
195
203
Figure 38 Dimensions for units 68A-68T.
EN 50022 mounting rail
49
170
115
Figure 39 Dimension for units 68U-Z and 69.
49
720 EXTRA DOCUMENTATION
Gxy Product Manual IRB 2400, including Product Specification.
60 Product Specification IRB 2400 M98/BaseWare OS 3.1
Accessories
5 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Software options for robot and PC
For more information, see Product Specification RobotWare.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
Product Specification IRB 2400 M98/BaseWare OS 3.1
61
Accessories
62 Product Specification IRB 2400 M98/BaseWare OS 3.1
Product Specification RobotWare
CONTENTS
Page
3.7 Load Identification and Collision Detection 3.1 (LidCode)................................... 24
Product Specification RobotWare for BaseWare OS 3.1
1
Product Specification RobotWare
8 Index................................................................................................................................. 79
2 Product Specification RobotWare for BaseWare OS 3.1
Introduction
1 Introduction
RobotWare is a family of software products from ABB Flexible Automation designed to make you more productive and lower your cost of owning and operating a robot.
ABB Flexible Automation has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations.
Within the RobotWare family there are five 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.
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.
DeskWare - This is a set of Windows-based PC products for a wide range of uses like: creating robot programs, training people on how to use robots, keeping track of robot programs and on-line documentation. The purpose is to lower the indirect cost of owning a robot.
FactoryWare - By combining the power of PCs with robots, the possibilities are almost unlimited. The FactoryWare products are intended to be used in PCs connected to robots, on the factory floor or in the office. These tools can be typically used for such things as programmable operator interfaces, work monitoring or cell supervision.
Product Specification RobotWare for BaseWare OS 3.1
3
Introduction
4 Product Specification RobotWare for BaseWare OS 3.1
Rapid Language and Environment
2 BaseWare OS
Only a very superficial overview of BaseWare OS is given here. For details, see references in Robot Documentation.
The properties of BaseWare OS can be split up in five main areas: The Rapid Language and Environment; Exception handling; Motion Control; Safety; the I/O System.
2.1 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).
Product Specification RobotWare for BaseWare OS 3.1
5
Exception handling
2.2 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.
6 Product Specification RobotWare for BaseWare OS 3.1
Motion Control
2.3 Motion Control
TrueMove TM
Very accurate path and speed, based on advanced dynamic modelling. Speed independent path. Flexible and intuitive way to specify corner zones (e.g. possibility to have separate zone sizes for Tool Centre Point (TCP) path and for tool reorientation).
QuickMove TM
By use of the dynamic model, the robot always and automatically optimises its performance for the shortest possible cycle time. No need for manual tuning! This is achieved without compromising the path accuracy.
Coordinate Systems
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 attached to the robot or fixed in the cell (“Stationary TCP”). Note that also joint coordinate movements
(MoveJ) are recalculated when a coordinate system is adjusted.
Singularity handling
The robot can pass through singular points in a controlled way, i.e. points where two axes coincide.
Motion Supervision
The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not
OK. A further monitoring function, Collision Detection, is optional (see option “Load
Identification and Collision Detection”).
External axes
Very flexible possibilities to configure external axes. Includes for instance high performance coordination with robot movement and shared drive unit for several axes.
Big Inertia
One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. For big, flexible objects it is possible to optimise the servo tuning to minimise load oscillation.
Product Specification RobotWare for BaseWare OS 3.1
7
Motion Control
Soft Servo
Any axis (also external) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour.
8 Product Specification RobotWare for BaseWare OS 3.1
Safety
2.4 Safety
Many safety concepts reside in hardware and are not within the scope of this document.
However, some important software contributions will be mentioned:
Reduced Speed
In the reduced speed mode, the controller limits all parts of the robot body, the TCP and one user defined point (attached to the upper arm) to 250 mm/s (can be set lower).
This limitation also works in joint system motion.
Motion Supervision
See Motion Control.
Authorisation
It is possible to limit the access to certain commands by assigning different passwords to four different user levels (operator, service, programmer, service & programmer). It is possible to define the commands available at the different levels.
Limited modpos
It is possible to limit the allowed distance/rotation when modifying positions.
Product Specification RobotWare for BaseWare OS 3.1
9
I/O System
2.5 I/O System
Elementary I/O
Robust and fast distributed system built on CAN/DeviceNet with the following features:
- Named signals and actions with mapping to physical signal (“gripper close” instead of “set output 1”).
- Flexible cross connections.
- Up to 512 signals available (one signal = single DI or DO, group of DI or DO,
AI or AO).
- Grouping of signals to form integer values.
- Sophisticated error handling.
- Selectable “trust level” (i.e. what action to take when a unit is “lost”).
- 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.
Serial I/O
XON/XOFF or SLIP.
Memory I/O
RAM disk and floppy disk.
10 Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1
3 BaseWare Options
3.1 Advanced Functions 3.1
Includes functions making the following possible:
- Information transfer via serial channels or files.
- Setting an output at a specific position.
- Executing a routine at a specific position.
- Defining forbidden areas within the robot´s working space.
- Automatic setting of output when the robot is in a user-defined area.
- Robot motion in an error handler or trap routine, e.g. during automatic error handling.
- Cross connections with logical conditions.
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.
Product Specification RobotWare for BaseWare OS 3.1
11
Advanced Functions 3.1
Data transfer via files
Data in the form of character strings, numerical values or binary information can be written to or read from files on a diskette or other type of mass storage/memory.
Examples of applications:
- Storing production statistics on a diskette or ramdisk. This information can then be read and processed by an ordinary PC.
- The robot’s production is controlled by a file. This file may have been created in a PC, stored on a diskette, and read by the robot at a later time.
Fixed position output
The value of an output (digital, analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. The output will then change at the same place every time, irrespective of the robot’s speed.
Consideration can also be given to time delays in the process equipment. By specifying this time delay (max. 500 ms), the output is set at the corresponding time before the robot reaches the specified position.
The distance can also be specified as a certain time before the programmed position.
This time must be within the deceleration time when approaching that position.
Examples of applications:
- Handling press work, to provide a safe signalling system between the robot and the press, which will reduce cycle times. Just as the robot leaves the press, an output is set that starts the press.
- Starting and finishing process equipment. When using this function, the start will always occur at the same position irrespective of the speed. For gluing and sealing, see GlueWare.
Fixed position procedure call
A procedure call can be carried out when the robot passes the middle of a corner zone.
The position will remain the same, irrespective of the robot’s speed.
Example of application:
- In the press example above, it may be necessary to check a number of logical conditions before setting the output that starts the press. A procedure which takes care of the complete press start operation is called at a position just outside the press.
12 Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1
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.
Product Specification RobotWare for BaseWare OS 3.1
13
Advanced Functions 3.1
Movements in interrupt routines and error handlers
This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one. The robot stores information about the original movement path which allows it to be resumed later.
Examples of applications:
- Cleaning the welding gun when a welding fault occurs. When a welding fault occurs, there is normally a jump to the program’s error handler. The welding movement in progress can be stored and the robot is ordered to the cleaning position so that the nozzle can be cleaned. The welding process can then be restarted, with the correct parameters, at the position where the welding fault occurred. This is all automatic, without any need to call the operator. (This requires options ArcWare or ArcWare Plus.)
- Via an input, the robot can be ordered to interrupt program execution and go to a service position, for example. When program execution is later restarted
(manually or automatically) the robot resumes the interrupted movement.
Cross-connections with logical conditions
Logical conditions for digital input and output signals can be defined in the robot’s system parameters using AND, OR and NOT. Functionality similar to that of a PLC can be obtained in this way.
Example:
- Output 1 = Input 2 AND Output 5.
- Input 3 = Output 7 OR NOT Output 8.
Examples of applications:
- Program execution to be interrupted when both inputs 3 and 4 become high.
- A register is to be incremented when input 5 is set, but only when output 5=1 and input 3=0.
14 Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1
RAPID instructions and functions included in this option
Open
Close
Write
WriteBin
WriteStrBin
ReadNum
ReadStr
ReadBin
Rewind
WZBoxDef
WZCylDef
WZLimSup
WZSphDef
WZDOSet
WZDisable
WZEnable
WZFree
StorePath
RestoPath
TriggC
TriggL
TriggJ
TriggIO
TriggEquip
TriggInt
MoveCSync
MoveLSync
MoveJSync
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
Define a box shaped world zone
Define a cylinder shaped world zone
Activate world zone limit supervision
Define a sphere shaped world zone
Activate world zone to set digital output
Deactivate world zone supervision
Activate world zone supervision
Erase world zone supervision
Stores the path when an interrupt or error occurs
Restores the path after an interrupt/error
Position fix output/interrupt during circular movement
Position fix output/interrupt during linear movement
Position fix output/interrupt during joint movement
Definition of trigger conditions for one output
Definition of trigger conditions for process equipment with time delay
Definition of trigger conditions for an interrupt
Position fix procedure call during circular movement
Position fix procedure call during linear movement
Position fix procedure call during join movement
Product Specification RobotWare for BaseWare OS 3.1
15
Advanced Motion 3.1
3.2 Advanced Motion 3.1
Contains functions that offer the following possibilities:
- Resetting the work area for an axis.
- Independent movements.
- Contour tracking.
- Coordinated motion with external manipulators.
Resetting the work area for an axis
The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements.
Examples of applications:
- When polishing, a large work area is sometimes needed on the robot axis 4 or axis 6 in order to be able to carry out final polishing without stopping. Assume that the axis has rotated 3 turns, for example. It can now be reset using this function, without having to physically rotate it back again. Obviously this will reduce cycle times.
- When arc welding, the work object is often fitted to a rotating external axis. If this axis is rotated more than one turn during welding, the cycle time can be reduced because it is not necessary to rotate the axis back between welding cycles.
Coordinated motion with multi-axis manipulators
Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires the Advanced Motion option. Note that simultaneous coordination with several single axis manipulators, e.g. track motion and workpiece manipulator, does not require
Advanced Motion.
Note! There is a built-in general method for defining the geometry for a manipulator comprising two rotating axes (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest ABB Flexible Automation
Centre.
16 Product Specification RobotWare for BaseWare OS 3.1
Advanced Motion 3.1
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.
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.
Product Specification RobotWare for BaseWare OS 3.1
17
Advanced Motion 3.1
External Drive System
With Advanced Motion, the possibility to connect off-the-shelf standard drive systems for controlling external axes is available. This can be of interest, for example, when the power of the available S4C drives does not match the requirements.
There are two alternatives:
- The Atlas Copco Controls´ stand alone servo amplifier DMC.
- The Atlas Copco Controls´ FBU (Field Bus Unit) that can handle up to three external drive units per FBU unit.
These can be connected to analog outputs (+/- 10 V) or a field bus.
The drive board can thus be of virtually any make and type.
For further information about DMC and FBU, please contact Atlas Copco Controls.
NOTE! The DMC/FBU must be equipped with Atlas Copco Controls option C.
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
18 Product Specification RobotWare for BaseWare OS 3.1
Multitasking 3.1
3.3 Multitasking 3.1
Up to 10 programs (tasks) can be executed in parallel with the normal robot program.
- These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode.
- They are programmed using standard RAPID instructions, except for motion instructions.
- They can be programmed to carry out various activities in manual or automatic mode, and depending on whether or not the main process is running.
- Communication between tasks is carried out via I/O or global data.
- Priorities can be set between the processes.
Examples of applications:
- The robot is continuously monitoring certain signals even when the robot program has stopped, thus taking over the job traditionally allocated to a PLC.
- An operator dialogue is required at the same time as the robot is doing, for example, welding. By putting this operator dialogue into a background task, the operator can specify input data for the next work cycle without having to stop the robot.
- The robot is controlling a piece of external equipment in parallel with the normal program execution.
Performance
When the various processes are programmed in the correct way, no performance problems will normally occur:
- When the priorities for the various processes are correctly set, the normal program execution of the robot will not be affected.
- Because monitoring is implemented via interrupts (instead of checking conditions at regular intervals), processor time is required only when something actually happens.
- All input and output signals are accessible for each process.
Note that the response time of Multitasking does not match that of a PLC. Multitasking is primary intended for less demanding tasks.
The available program memory can be divided up arbitrarily between the processes.
However, each process in addition to the main process will reduce the total memory, see section 5.1.
Product Specification RobotWare for BaseWare OS 3.1
19
FactoryWare Interface 3.1
3.4 FactoryWare Interface 3.1
This option enables the robot system to communicate with a PC using RobComm 3.0 or later versions (see FactoryWare). The FactoryWare Interface 3.1 serves as a run-time license for RobComm, i.e. the PC does not require any license protection when executing a RobComm based application. However, when developing such an application, a hardware lock and password are needed in the PC (design time license).
Older versions of RobComm will require RAP Communication in the robot and license protection in the PC (hardware lock and password for design and run-time, or only password for only run-time).
This option will also work with RobView 3.1/1 or DDE Server 2.3/1 (or later versions).
Older versions work only with RAP Communication. In all cases RobView and DDE
Server will require the hardware lock and password.
The Factory Ware Interface 3.1 includes the Robot Application Protocol (RAP), based on MMS functionality. The Robot Application Protocol is used for computer communication. The following functions are supported:
- Start and stop program execution
- Transfer programs to/from the robot
- Transfer system parameters to/from the robot
- Transfer files to/from the robot
- Read the robot status
- Read and write data
- Read and write output signals
- Read input signals
- Read error messages
- Change robot mode
- Read logs
RAP communication is available both for serial links and network, as illustrated by the figure below.
RAP
RPC (Remote Procedure Call)
TCP/IP
SLIP
RS232/RS422
Ethernet
Standard protocols
20 Product Specification RobotWare for BaseWare OS 3.1
FactoryWare Interface 3.1
Examples of applications:
- Production is controlled from a superior computer. Information about the robot status is displayed by the computer. Program execution is started and stopped from the computer, etc.
- Transferring programs and parameters between the robot and a PC. When many different programs are used in the robot, the computer helps in keeping track of them and by doing back-ups.
- Programs can be transferred to the robot’s ramdisk at the same time as the robot executes its normal program. When execution of this program has finished, the new program can be read very quickly from the ramdisk and program execution can continue. In this way a large number of programs can be handled and the robot’s memory does not have to be so big.
RAPID instruction included in this option
SCWrite Sends a message to the computer (using RAP)
Product Specification RobotWare for BaseWare OS 3.1
21
RAP Communication 3.1
3.5 RAP Communication 3.1
This option is required for all communication with a superior computer, where none of the FactoryWare products RobComm, RobView, or DDE Server, are used. It includes the same functionality described for the option Factory Ware Interface 3.1.
It also works for the FactoryWare products. For RobView and DDE Server, there is no difference from the FactoryWare Interface (except that the price is higher). For
RobComm, in this case a license protection requirement in the PC is added.
Note that both FactoryWare Interface and RAP Communication can be installed simultaneously.
22 Product Specification RobotWare for BaseWare OS 3.1
Ethernet Services 3.1
3.6 Ethernet Services 3.1
Information in mass storage, e.g. the hard disk in a PC, can be read directly from the robot. The robot control program can also be booted via Ethernet instead of using diskettes. This requires Ethernet hardware in the robot.
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.
Product Specification RobotWare for BaseWare OS 3.1
23
Load Identification and Collision Detection 3.1 (LidCode)
3.7 Load Identification and Collision Detection 3.1 (LidCode)
This option is only available for the IRB 6400 family of 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
ParldRobValid
ParldPosValid
LoadId
Changing the sensitivity of the collision detection or activating/deactivating the function.
Checking that identification is available for a specific robot type.
Checking that the current position is OK for identification.
Performing identification.
24 Product Specification RobotWare for BaseWare OS 3.1
ScreenViewer 3.1
3.8 ScreenViewer 3.1
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: ###
File
PHASES
SQUEEZE
PREHEAT
COOLING
## HEAT
COLD
LASTCOLD
POSTHEAT
HOLD
| X T
| ##
| ##
| ##
| ##
| ##
| ##
| ##
| ##
| CURENT (A)
| START
|
| END
|
| ####
|
| ####
|
|
| ####
|
|
|
| ####
|
|
| ####
|
View
Heat stepper: ### interpolated: ##
|
| Tolerance: ###%
| Force: ###daN
| Forge: ###daN
|
| Fire chck: ###
|
| Err allow: ###%
| Numb err: ###
Next Prev.
(Copy) Valid
Product Specification RobotWare for BaseWare OS 3.1
25
ScreenViewer 3.1
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.
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).
26 Product Specification RobotWare for BaseWare OS 3.1
Conveyor Tracking 3.1
3.9 Conveyor Tracking 3.1
Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor. While tracking the conveyor, the programmed TCP speed relative to the work object will be maintained, even when the conveyor speed is changing slowly.
Note that hardware components for measuring the conveyor position are also necessary for this function. Please refer to the Product Specification for your robot.
Conveyor Tracking provides the following features:
- A conveyor can be defined as either linear or circular.
- It is possible to have two conveyors connected simultaneously and to switch between tracking the one or the other.
- Up to 254 objects can reside in an object queue which can be manipulated by
RAPID instructions.
- It is possible to define a start window in which an object must be before tracking can start.
- A maximum tracking distance may be specified.
- If the robot is mounted on a parallel track motion, then the system can be configured such that the track will follow the conveyor and maintain the relative position to the conveyor.
- Tracking of a conveyor can be activated “on the fly”, i.e. it is not necessary to stop in a fine point.
Performance
At 150 mm/s constant conveyor speed, the TCP will stay within +/-2 mm of the path as seen with no conveyor motion. When the robot is stationary relative to the conveyor, the TCP will remain within 0.7 mm of the intended position.
These values are valid as long as the robot is within its dynamic limits with the added conveyor motion and they require accurate conveyor calibration.
RAPID instructions included in this option
WaitWObj
DropWObj
Connects to a work object in the start window
Disconnects from the current object
Product Specification RobotWare for BaseWare OS 3.1
27
I/O Plus 3.1
3.10 I/O Plus 3.1
I/O Plus enables the S4C to use non-ABB I/O units. The following units are supported:
- Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3.
- Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2
(16 digital input signals).
- Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1
(8 digital input signals and 8 digital output signals).
For more information on any of these untis, please contact the supplier.
The communication between these units and S4C has been verified (this does not, however, guarantee the internal functionality and quality of the units). Configuration data for the units is included.
In I/O Plus there is also support for a so-called “Welder”. This is a project specific spot welding timer, and is not intended for general use.
In addition to the above units, the I/O Plus option also opens up the possibility to use other digital I/O units that conform with the DeviceNet specification. ABB Robotics
Products AB does not assume any responsibility for the functionality or quality of such units. The user must provide the appropriate configuration data.
28 Product Specification RobotWare for BaseWare OS 3.1
ArcWare 3.1
4 ProcessWare
4.1 ArcWare 3.1
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 for BaseWare OS 3.1
29
ArcWare 3.1
Wire burnback and rollback
These are functions used to prevent the welding wire sticking to the work object.
Fine adjustment during program execution
The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst welding is in progress. This makes trimming of the process much easier because the result can be seen immediately on the current weld. This can be done in both manual and automatic mode.
Weld Guiding
Weld guiding can be implemented using a number of different types of sensors. Please contact your nearest ABB Flexible Automation Centre for more information.
30
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.
Digital outputs
Power on/off
Gas on/off
Wire feed on/off
Wire feed direction
Weld error
Error information
Weld program number
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
Analog outputs
Voltage
Wire feed
Current
Voltage adjustment
Current adjustment
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
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
Description
Weld voltage
Velocity of wire feed
Weld current
Voltage synergic line amplification
Current synergic line amplification
Product Specification RobotWare for BaseWare OS 3.1
ArcWare 3.1
Analog inputs (cont.)
Voltage
Current
Description (cont.)
Weld voltage measurement for monitoring and supervision
Weld current measurement for monitoring and supervision
RAPID instructions included in this option
ArcL
ArcC
Arc welding with linear movement
Arc welding with circular movement
Product Specification RobotWare for BaseWare OS 3.1
31
ArcWare Plus 3.1
4.2 ArcWare Plus 3.1
ArcWare Plus contains the following functionality:
- ArcWare, see previous chapter.
- Arc data monitoring.
Arc data monitoring with adapted RAPID instructions for process supervision.
The function predicts weld errors.
- Contour tracking.
Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion.
Example of application:
A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted.
- Adaptive process control.
Adaptive process control for LaserTrak and Serial Weld Guide systems. The tool provides the robot system with changes in the shape of the seam. These values can be used to adapt the process parameters to the current shape.
RAPID instructions and functions included in this option
ArcKill
ArcRefresh
CorrCon
CorrWrite
CorrRead
CorrDiscon
CorrClear
SpcCon
SpcWrite
SpcDump
SpcRead
SpcDiscon
Aborts the process and is intended to be used in error handlers
Updates the weld references to new values
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
32 Product Specification RobotWare for BaseWare OS 3.1
SpotWare 3.1
4.3 SpotWare 3.1
SpotWare comprises a large number of dedicated spot welding functions which make the robot well suited for spot welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction.
Cycle times can be shortened by means of closing the spot welding gun in advance, together with the fact that movement can commence immediately after a spot weld is completed. The robot’s self-optimising motion control, which results in fast acceleration and a quick approach to the spot weld, also contributes to making cycle times shorter.
I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation.
SpotWare functions
A few examples of some useful functions are given below.
Adaptation to different welding guns
Gun control (opening and closing) can be programmed freely to suit most types of guns, irrespective of the signal interface.
Adaptation to different weld timers
The robot can handle different types of weld timers. Normally communication with the weld timer uses parallel signals but a serial interface is also available for some types of weld timers.
Continuous supervision of the welding equipment
If the option Multitasking is added, supervision can be implemented irrespective of the spotweld instruction. For example, it is possible to monitor peripheral equipment even when program execution has been stopped.
Closing the gun
It is possible to start closing the spot welding gun before reaching the programmed point. By defining a time of closure, the gun can be closed correctly regardless of the speed of the robot. The cycle time is optimised when the gun is just about to close at the instant when the robot reaches the programmed point.
Constant squeeze time
Welding can be started directly as the gun closes, i.e. without waiting for the robot to reach its final position. This gives a constant time between gun closure and weld start.
Customised Move enable
The movement after a completed spot weld can be configured to start either on a user defined input signal or a delay time after weld ready.
Product Specification RobotWare for BaseWare OS 3.1
33
SpotWare 3.1
Immediate move after Move enable
The robot moves immediately when enable is given. This is achieved by preparing the next action while waiting for the current weld to be completed.
Gun control
The system supports double guns, small and large strokes and gun pressure control.
Several guns can be controlled in the same program.
Testing the program
The program can be run one instruction at a time, both forwards and backwards. When it is run backwards, only motion instructions, together with an inverted gun movement, are executed. The program can also be test run without connecting a weld timer or spot welding gun. This makes the program easier to test.
Rewelds
A function that can be configured to order one or more automatic rewelds or, when the program is restarted after an error, a manual reweld.
Process error routines
In the event of a process error, installation-specific routines, such as go-to-service position, can be ordered manually. When the appropriate routine has been performed, the weld cycle continues from where it was interrupted.
Manual welding independent of positioning
A spot weld can be ordered manually at the current robot position. This is implemented in a similar way as for program execution, i.e. with gun control and process supervision. It is also possible to order a separate gun control with full supervision.
Interface signals
The following process signals are, if installed, handled automatically by SpotWare.
Digital outputs start 1 start 2 close tip 1 close tip 2 work select program parity reset fault process error current enable p2 request p3 request p4 request weld power water start
Description start signal to the weld timer (tip 1) start signal to the weld timer (tip 2) close gun (tip 1) close gun (tip 2) select work or retract stroke of the gun weld program parity bit reset the weld timer operator request is set when an error occurs weld inhibit to the weld timer set pressure 2 set pressure 3 set pressure 4 activate the weld power unit contactor activate water cooling
34 Product Specification RobotWare for BaseWare OS 3.1
SpotWare 3.1
manual close gun manual open gun manual run process manual skip process manual new data process run inhibit move weld error
Digital output groups program no.
initiate
Digital inputs weld ready 1 weld ready 2 tip 1 open tip 2 open tip 1 retract tip 2 retract p1 OK p2 OK p3 OK p4 OK timer OK flow OK temp OK current OK close gun manually open gun manually run a complete spot weld skip the ongoing action send data for the manual actions process is executed block spot welding movement weld ready timeout
Description weld program number used for several weld timers
Description weld, started with start 1, is finished weld, started with start 2, is finished the gun (tip 1) is open the gun (tip 2) is open the gun (tip 1) opened to retract stroke the gun (tip 2) opened to retract stroke pressure 1 is reached pressure 2 is reached pressure 3 is reached pressure 4 is reached the weld timer is ready to weld no problem with the water supply no over-temperature the weld current is within permissible tolerances
User defined routines
The following routines are predefined but can be adapted to suit the current installation.
Routine preweld supervision postweld supervision init supervision motor on action motor off action process OK action process error action current enable action current disable action close gun open gun set pressure service close gun service open gun service weld fault
The option Advanced functions is included.
Description supervision to be done before welding supervision to be done after welding supervision to be done for a warm start action to be taken for Motors On action to be taken for Motors Off action to be taken for welding sensor OK action to be taken for a process error action to be taken for current enable action to be taken for current disable definition of gun closing definition of gun opening definition of gun pressure setting error handling when gun pressure is not achieved error handling at timeout for gun opening error handling at timeout for weld-ready signal
Product Specification RobotWare for BaseWare OS 3.1
35
SpotWare 3.1
RAPID instructions included in this option
SpotL Spot welding with linear movement
36 Product Specification RobotWare for BaseWare OS 3.1
SpotWare Plus 3.1
4.4 SpotWare Plus 3.1
In addition to the SpotWare functionality the robot can weld with up to four stationary welding guns simultaneously.
RAPID instructions included in this option
SpotML Multiple spot welding with linear movement.
Product Specification RobotWare for BaseWare OS 3.1
37
GlueWare 3.1
4.5 GlueWare 3.1
GlueWare comprises a large number of dedicated gluing functions which make the robot well suited for gluing and sealing. It is a simple yet powerful program since both the positioning of the robot and the process control are handled in one and the same instruction.
I/O signals and timing sequences can be easily configured to meet the requirements of a specific installation.
GlueWare functions
A few examples of some useful functions are given below.
Adaptation to different gluing guns
Both on/off guns and proportional guns can be handled. Furthermore, time delays can be specified for the gluing guns in order to obtain the correct thickness of glue or sealing compound and application at the specified time.
Two gluing guns
One or two gluing guns can be controlled. Up to two analog outputs can be controlled for each gun.
Velocity independent glue string thickness
The thickness of the glue string can be made independent on the robot’s velocity by controlling the gluing gun with a signal that reflects the robot’s velocity. When the robot velocity is reduced, the flow of glue will be automatically reduced. The robot can compensate for a gun delay of up to 500 ms, thanks to a proactive signal.
Flow change at a specific position
Flow changes (incl. start and stop) can be put into the programmed path, also where there are no programmed positions. These positions will remain fixed even when the velocity is changed, which makes the programming much simpler.
Global flow changes
The glue flow can be changed for the whole program just by changing one value.
Program testing without glue
Gluing can be temporarily blocked in order to be able to test the robot’s movements without any glue flow.
38 Product Specification RobotWare for BaseWare OS 3.1
GlueWare 3.1
Interface signals
When installed, the following process signals are handled automatically by GlueWare.
Analog outputs gun1 flow1 gun1 flow 2 gun2 flow1 gun2 flow 2
Digital outputs gun 1 on/off gun 2 on/off overspeed error process error
Description
Glue flow reference gun 1
Glue flow reference gun 1
Glue flow reference gun 2
Glue flow reference gun 2
Description glue off/on gun1 glue off/on gun 2 the calculated value of an analog output signal is greater than its logical max. value error during gluing
User defined routines
The following routines are predefined but can be adapted to suit the current installation.
Routine preglue actions postglue actions power on action restart action stop action emergency stop action
Description activity to be carried out in the beginning of the glue string activity to be carried out at the end of the glue string activity to be carried out at power-on activity to be carried out at program start activity to be carried out at program stop activity to be carried out in the event of an emergency stop or other safeguarded space stop
The option Advanced functions is included.
RAPID instructions included in this option
GlueL
GlueC
Gluing with linear movement
Gluing with circular movement
Product Specification RobotWare for BaseWare OS 3.1
39
PaintWare 3.1
4.6 PaintWare 3.1
PaintWare comprises a large number of dedicated painting functions which make the robot well suited for painting and coating operations. It is powerful, yet simple since both the robot positioning and the paint events are handled in one and the same instruction. All phases of the paint process are controlled, such as start, change, and stop painting, due to trig plane events.
The necessary structures for paint process data are predefined and organised as
BrushData and BrushTables.
PaintWare is only avaliable with painting robots.
PaintWare functionality
When painting, the fluid and air flow through the spray gun is controlled to suit the part being coated and the thickness requirements. These process parameters are changed along the path to achieve optimum control of the paint equipment along an entire path.
The paint process is monitored continuously.
A set of gun process parameters is called a Brush and it is possible to select different brushes during a linear paint instruction. A brush can contain up to five parameters:
Paint
Atom_air
Fan_air
Voltage
Rotation
The Paint flow reference.
The Atomising air reference.
The Fan air reference.
The Electrostatic voltage reference.
The Rotation speed reference (for rotational applicators).
The five parameters may go directly to analog outputs controlling the spray gun in an open loop system, or may go to dedicated I/O boards for closed loop gun control (IPS).
The Brushes are set up as an array, called a BrushTable. A specific BrushTable is selected with the instruction UseBrushTab.
The changing of brushes along a path is done using events in the PaintL instruction. The event data describes how a trig plane is located in the active object coordinate system.
It also describes which brush to use when the path crosses the plane. Event data is included in all linear paint instructions as optional arguments. A maximum of ten events can be held within one PaintL instruction.
Data types included in this option
BrushData
EventData
Data for one brush: flow, atomising air, fan air, etc.
Data for one event: trig-plane (x, y or z), plane value and brush numberPaintL, PaintC, UseBrushTab,
40 Product Specification RobotWare for BaseWare OS 3.1
PaintWare 3.1
RAPID instructions included in this option
PaintL
PaintC
UseBrushTab
SetBrush
Paint along a straight path w/paint events
Paint along a circular path
Used to activate (select) a brush-table.
Select a brush from the activated brush-table.
Product Specification RobotWare for BaseWare OS 3.1
41
4.7 PalletWare
General
The PalletWare package is a set of Rapid modules and user screens, which perform basic operations related to a palletizing process. These operations include a number of services which can be called from a main program to perform pick and place operations for one or up to five palletizing tasks in parallel. For each such task a number of separate dynamic variables are used to describe and keep track of each on-going pallet operation. The PalletWare package is intended to work with Rapid modules generated from PalletWizard, a PC tool for off-line programming of pallet cycles.
Pallet cycles
Up to five different pallet cycles may be run in parallel, where a pallet cycle is the task to run a complete palletizing job for a pallet, i.e. to pick and place all products, including the pallet itself.
Each pallet cycle includes a number of layer cycles, where each layer cycle is the task to complete one layer with all the parts to be picked and placed in this layer.
Each layer cycle may further be broken down into a number of pick-place cycles, where each pick-place cycle is the task to pick one or several parts and place them on the pallet. Within each pick-place cycle there may be several pick operations, if parts must be picked in many separate operations. Similarly, there may be several place operations in each pick-place cycle.
Each layer may be either an in-feeder layer, where the products, e.g. boxes, are picked from an in-feeder, or a stack layer, where the product, e.g. an empty pallet, is searched and picked from a stack.
If several pallet cycles are run in parallel, then one complete pick-place cycle is always finished before a new one is started in another pallet cycle.
Pallet cell
The pallet cell may include any number of pallet stations, in-feeders and stacks for pallets, tier sheets or slip sheets. All such stations and stacks are defined as regards position, with an individual coordinate system (work object).
The palletizing robot is normally an IRB 6400 or IRB 640 but any robot type may be used. The tool to use may be a mechanical gripper or a tool with suction cups, possibly with separate grip zones for multiple picking and placing. Several different tooldata may be defined and used depending on the product dimensions and number of products.
42 Product Specification RobotWare for BaseWare OS 3.1
Products
Any number of different products with different dimensions may be handled and placed in different patterns on the pallet. Each layer must have the same product only, but different layers on a pallet may have different products.
Products may be delivered on one or several in-feeders and placed on one or several different pallets.
For each separate product individual handling speeds and load data are used.
The dimensions and speeds of the products may be changed in run time, thus affecting all pick and place positions.
Movements, approach and retreat positions
All movements are calculated in run time and relative to the different coordinate systems defined for each station. Between stations, e.g. moving from an in-feeder to a pallet station, the robot may be forced to move up to safety height and to retract before moving towards the new station. While moving to the pick or place position, the robot will first move to an approach position and then to a prepick/place position. These horizontal and vertical distances for the approach positions, relative to the pick or place position, may be individually defined per product or station. In addition, the approach direction may be individually defined per pick or place position. These approach data may be changed in run time.
The picking and placing movements and the sequence to search different stacks for empty pallets or tier sheets may be customised if necessary.
User routines
A number of different user routines may be called at certain phases of the pallet cycle.
These routines can be used for communication with external equipment, for error checking, for operator messages etc. Such user routines are grouped in three main groups according to when they are called in the pallet cycle. The groups are:
- Cycle routines, connected to the different cycles, i.e. pallet cycle, layer cycle, pick and place cycle. Each such cycle may have its own individual user routine at the beginning, at the middle and at the end of the cycle.
- Station access routines, connected to the different stations. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place on a feeder or pallet station, e.g. to order the next products on the feeder.
- Pick stack routines, connected to stacks. Such routines are called to search and pick a product on the stack.
Product Specification RobotWare for BaseWare OS 3.1
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44
User screens
The user interacts with the program using menu driven screens on the teach pendant.
These screens allow the following functions to be configured:
- Station menu gives access to the robot default parameters, the tool information, the pallet stations, stack stations and feeder station information.
- Product menu gives access to the information related to the different types of product: regular products, empty pallets.
- Cycles menu gives access to the current production status for the different lines.
PalletWare system modules
PalletWare consists of a number of system modules as listed below.
PalletWare Kernel: PAL_EXE.sys
Generated from PalletWizard:
PAL_DYN.sys
PAL_SCR.sys
PAL_CELL.sys
PAL_CYC.sys
Templates to be completed by the system integrator concerning work object data, tool data, user routines including communication with external equipment etc.:
PAL_USRR.sys
PAL_USRT.sys
Modules and code not included in PalletWare
In addition to the modules listed above, there are some modules which are not included in the PalletWare delivery, but which must be written by the system integrator for specific installations. These are:
- The “main” module, including the main routine. In this routine all logic for working with parallel and simultaneous pallet cycles must be coded by the system integrator, including code required for operator messages, error handling and product changes.
- A system module holding different operator dialogues, which may be called from the main routine in order to change or check pallet cycles or to handle error situations.
System requirements for option PalletWare
- Option ScreenViewer.
Product Specification RobotWare for BaseWare OS 3.1
Available memory
5 Memory and Documentation
5.1 Available memory
The available user memory for the different memory options is as follows:
Extended memory Standard
Total memory
Program memory without options
8+8=16 MB
(option 402)
2.5 MB
(ram disk=0.5 MB)
+8 MB
8+16=24 MB
(option 403)
6.0 MB
(ram disk=4.0 MB)
Other software options reduce the available program memory as follows. Options not mentioned have no or small memory consumption (less than 10 kB). All the figures are approximate.
Multitasking
Advanced Functions
GlueWare
Option
Base system
SpotWare
SpotWare Plus
SpotWare Plus
Load Identification and
Collision Detection
Program memory
335 kB
Ram disk
145 kB (225 kB if memory option 403 is chosen)
80 kB/task (including task 1)
20 kB
125 kB 30 kB
370 kB
390 kB
730 kB
55 kB
75 kB
75 kB
Remark
Including Advanced
Functions
Including Multitasking with two spotware tasks (one process and one supervision task).
Including Multitasking with two spotware tasks (one process and one supervision task).
Including Multitasking with five spotware tasks (four process and one supervision task).
80 kB 40 kB
Product Specification RobotWare for BaseWare OS 3.1
45
Teach pendant language
For RAPID memory consumption, see the 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.
5.2 Teach Pendant Language
The robot is delivered with the selected language installed. The other languages are also delivered and can be installed.
5.3 Robot Documentation
A complete set of documentation consisting of:
- User’s Guide, with step by step instructions on how to operate and program the robot. This manual also includes a chapter called Basic Operation, which is an introduction to the basic operation and programming of the robot, and is suitable as a tutorial.
- RAPID Reference Manual, a description of the programming language.
- Product Manual, a description of the installation of the robot, maintenance procedures and troubleshooting. The Product Specification is included.
If the Danish language is chosen, the RAPID Reference Manual and parts of the
Product Manual will be in English.
46 Product Specification RobotWare for BaseWare OS 3.1
DeskWare Office 3.0
6 DeskWare
6.1 DeskWare Office 3.0
DeskWare Office is a suite of powerful PC applications designed to reduce the total cost of robot ownership. These applications are organized into four different rooms:
• Programming Station
• Training Center
• Library
• Robot Lab
These rooms contain PC-based tools for training, programming, testing, and maintenance to address the fundamental needs of all robot owners. A comprehensive list of all applications in the DeskWare Office suite, organized by room, follows below.
• Programming Station
- ProgramMaker application
- ConfigEdit application
- Online version of the S4 RAPID Reference Manual
• Training Center
- QuickTeach application
- QuickTeach Tutorial application
- Online version of the S4 User’s Guide
• Library
- ProgramSafe application
- ServiceLog application
- Online versions of all S4 documentation
• Robot Lab
- VirtualRobot application
To make navigating and launching applications easy, the graphical Office interface shown below was created.
To launch applications, the user clicks on corresponding “hot spots,” enabled when the rooms are installed. When you launch DeskWare applications, you are in fact running the Virtual Controller - the actual S4 controller software - in your PC.
Product Specification RobotWare for BaseWare OS 3.1
47
DeskWare Office 3.0
Training Center
User Preferences
Library
Robot Lab
Programming
Station
48 Product Specification RobotWare for BaseWare OS 3.1
DeskWare Office 3.0
The “User Preferences” button is used to select robot and language options that apply to the entire application suite. Pressing this button displays the following dialog.
Select a robot
Configure the selected robot
The following sections contain more detailed descriptions of the applications available in each room of the DeskWare Office suite.
PC System Requirements
- Pentium processor.
- 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 150 MB harddisk space.
- VGA compatible display (1024 x 768 recommended).
- CD-ROM drive.
- Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Programming Station 3.0
6.2 Programming Station 3.0
Programming Station is a collection of software applications that assist the user in constructing and editing robot programs and configuration files on a PC.
Programming Station includes:
- ProgramMaker application.
- ConfigEdit application.
- Online version of the S4 RAPID Reference Manual.
ProgramMaker allows the user to create and edit robot programs on a PC, in the
Windows environment.
ProgramMaker is a complete system for creating and editing RAPID programs for the
S4 robot controller. ProgramMaker is unique, compared to other offline programming systems, as it embeds the functionality of the S4 robot controller and uses this capability to perform all robot controller-specific tasks. For example, you can configure the embedded S4 controller within ProgramMaker so that it represents the same I/O setup as your real robot. Then, when you program I/O-based statements,
ProgramMaker checks to ensure that you refer only to those signals that are defined on your robot.
ProgramMaker can assume the functionality of different versions of the S4 controller, for example, V2.1 or V3.0, and behave in accordance with the features specific to that version of controller. This means you can see the same status and error messages in
ProgramMaker as you see on the real robot.
ProgramMaker implements an advanced Windows user interface that permits you to develop RAPID programs quickly, easily, and without error. Unlike using a conventional text editor, ProgramMaker helps you write RAPID programs by creating instructions with a single command, providing default parameters in many cases automatically. For beginning programmers, ProgramMaker provides instructionsensitive dialogs that make programming complex statements easy. For experts,
ProgramMaker also offers the more conventional approach of text-based entry of
RAPID program statements. Using either method, ProgramMaker guarantees that your programs will be valid when you load them into your robot.
You can set up ProgramMaker to assume the configuration of a specific robot controller. You do this using the Preferences dialog of Office. Configuration includes, for example, the specific version (V2.1, V3.0, etc.) of the robot controller, the software options installed on that controller (ArcWare, SpotWare, Serial RAP, etc.), and the amount of memory installed (10MB, 12MB, etc.). The Preferences dialog can be used to select a predefined configuration, or it can be used to create entirely new configurations through user-assisted dialogs or through direct import from the floppy disks shipped with your robot.
The following image illustrates some of the main features of the ProgramMaker user interface.
50 Product Specification RobotWare for BaseWare OS 3.1
Editing of background tasks is supported with a tabbed Tree
View.
Programming Station 3.0
Data View permits manipulation of program data in familiar
“spreadsheet” context.
Code View allows creation and editing of user programs.
Tree View provides a hierarchical view of
RAPID modules.
Graph View displays programmed points in a dynamic viewer.
Some of the main features of ProgramMaker include:
- Ability to check for syntactic and semantic errors, as robot programs are created or edited.
- Program data is displayed in a familiar “spreadsheet” format which is Microsoft
Excel compatible.
- Full support for RAPID array handling.
- Automatic declaration of referenced data.
- Positions can also be viewed as points in the Graph View.
- The Tree View allows the user to view and navigate robot program structure in a simple, logical manner.
- Syntax colorization in the Code View for enhanced usability.
- Multiple routines can be viewed and edited at the same time.
- Cut/Copy/Paste and Search/Replace features.
Product Specification RobotWare for BaseWare OS 3.1
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Programming Station 3.0
PalletWizard is a programming tool used for palletizing applications. It must be used in combination with PalletWare (i.e. the output generated from PalletWizard is used in conjunction with PalletWare).
PalletWizard is an integrated component of ProgramMaker, invoked from the ‘Tools’ menu.
PalletWizard allows the user to create and edit system modules, which define the layout of a palletizing robot cell with its different pallet stations, infeeders, stacks and tools, including the pallet composition (products, layers and layer patterns).
A robot cell for palletizing incorporates one palletizing robot, one or several pallet stations where products are placed and one or several infeeders, from which products are picked. The cell may also include one or several stacks, from which empty pallets or tier sheets are drawn.
Objects in a palletizing cell
The following objects and properties for a palletizing cell may be defined using
PalletWizard:
• Robot
- Speed without products
- Acceleration without products
• Pallet Stations
Several pallet stations may be defined, each with the following properties
- Maximum and minimum height
- Approach height
• Infeeders
Several infeeders may be defined, each with the following properties
- Maximum and minimum height
- Approach height
- Product alignment
- Type of product
• Stacks
Several stacks may be defined, each with the following properties
- Maximum and minimum height
- Approach height
- Product alignment
- Type of product
52 Product Specification RobotWare for BaseWare OS 3.1
Programming Station 3.0
• Products
A number of different products, for example, boxes, pallets, tier sheets etc., may be defined, each with the following properties:
- Size
- Sides with labels
- Robot speed and acceleration when carrying the product
- Pick and place approach distances, vertically and horizontally
Pallet cycles
A number of different pallet cycles may be defined. A pallet cycle consists of palletizing a complete pallet (i.e. to pick and place all products, including the pallet itself).
Each pallet cycle includes a number of layer cycles. Each layer cycle consists of one complete layer with all the products to be picked and placed in this layer.
Each layer cycle may further be broken down in a number of pick-place cycles, where each pick-place cycle consists of picking one or several parts and placing them on the pallet. Within each pick-place cycle there may be several pick operations, if parts should be picked in separate operations. Similarly, there might be several place operations in each pick-place cycle.
A number of different layer cycles may be defined, including pick-place cycles. These layer cycles may then be freely used and combined in different pallet cycles (pallet compositions).
For each layer cycle the following properties may be defined:
- The product to pick and place.
- The infeeder to use. Several infeeders may be used, if necessary.
- The pattern to use.
- The pick-place cycles to use.
For each pattern the following properties may be defined:
- The number of parts to place.
- The position and orientation of each part. Part positions are always related to reference lines, freely positioned on the pallet. Any number of reference lines and positions are allowed. Label sides of the articles may be placed facing out.
- The envelope of the pattern (i.e. the outer borders of the pattern).
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Programming Station 3.0
For each pick-place operation the following properties may be defined:
- The number of pick operations
- The number of place operations
- The tool to be used. Different tool definitions may be used depending on the article to pick and the number of articles.
- The approach direction for pick and place operations
- The pick and place positions, related to the used pattern
For each pallet cycle the following properties may be defined:
- The pallet station to use. Several pallet stations may be used, alternately, if necessary.
- The pallet to use in the first layer.
- Orientation of the pallet in the pallet station
- Load alignment (i.e. alignment of the pattern envelope - front, center or back, left, center or right).
- The pallet composition for a complete pallet (i.e. specification of layer cycles to use in each layer).
User routines
It is possible to call different user routines in different phases of the pallet cycle. These user routines may be used for installation specific tasks, for example, communication with external equipment, operator messages, intermediate positions, etc. In
PalletWizard, only the declarations of these user routines are created. The routine body, or RAPID code, can then be completed within ProgramMaker.
All routines are grouped in three main categories, according to when they are called in the pallet cycle. The groups are:
- Cycle routines, connected to the different cycles (pallet cycle, layer cycle, pick and place cycle). Each such cycle may have its own individual user routine in the beginning, in the middle, and at the end of the cycle.
- Station access routines, connected to the different stations. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place action on a feeder or pallet station, for example, to order the next products on the feeder.
- Pick stack routines, connected to stacks. Such routines are called to search and pick a product on the stack.
Load data
Load data (load, center of gravity, and moment of inertia) is automatically set up by
PalletWizard depending on the article dimensions, weight and number of articles in the tool.
54 Product Specification RobotWare for BaseWare OS 3.1
Programming Station 3.0
Output from PalletWizard
PalletWizard generates three output files, which are loaded into a robot system running
PalletWare.
ConfigEdit allows users to create and edit robot configuration files on a PC, in the
Windows environment.
Some of the main features of ConfigEdit include:
- Support for all configuration domains.
- Standard configuration templates which can be customized.
- Cut/Copy/Paste functions.
- Help feature to explain configuration parameters.
PC System Requirements
- Pentium processor.
- 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 100 MB harddisk space.
- VGA compatible display (1024 x 768 recommended).
- CD-ROM drive.
- Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Training Center 3.0
6.3 Training Center 3.0
Training Center is a collection of PC software applications that assist the user in learning how to use the robot.
Training Center includes:
- QuickTeach application.
- QuickTeach Tutorial application.
- Online version of the S4 User’s Guide.
QuickTeach is the actual teach pendant software running on a PC under Windows.
Most things that can be done on the real teach pendant can also be done with
QuickTeach, making QuickTeach an excellent training tool and eliminating the need to dedicate a robot for most training purposes.
56
Some of the main features of QuickTeach include:
- Supports all languages that are supported by the robot controller.
- Can be configured to emulate the real robot (i.e. custom menus, software options, etc.).
- Can be used to create and edit robot programs; however, Programming Station is more efficient for this purpose.
QuickTeach Tutorial is a 45 minute tutorial that covers the basic operations of the teach pendant. The tutorial is supported in the following languages:
- English, French, German, Italian, Spanish and Swedish.
Product Specification RobotWare for BaseWare OS 3.1
Training Center 3.0
PC System Requirements
- Pentium processor.
- 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 100 MB harddisk space.
- VGA compatible display (1024 x 768 recommended).
- CD-ROM drive.
- Microsoft compatible mouse.
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Library 3.0
6.4 Library 3.0
Library is a collection of PC software applications that allow the user to store and retrieve important documentation related to the robot and auxiliary equipment.
Library includes:
- ProgramSafe application.
- ServiceLog application.
Online versions of all S4 documentation.
ProgramSafe allows the user to archive, catalog and retrieve robot programs and configuration files in the Windows environment.
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Some of the main features of ProgramSafe include:
- Associate RAPID program and configuration files with individual robots.
- Compare feature to find the differences between files or different versions of the same file.
- File printout feature.
Product Specification RobotWare for BaseWare OS 3.1
Library 3.0
ServiceLog allows the user to archive, catalog and retrieve robot programs and configuration files in the Windows environment.
Some of the main features of ServiceLog include:
- Store maintenance information about robots and other workcell equipment.
- Store frequently used service-related names, addresses and phone numbers.
- Schedule future maintenance with automatic notification when due.
- ServiceLog data files are Microsoft Access compatible.
- User definable password protection with two security levels.
PC System Requirements
- Pentium processor.
- 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 30 MB harddisk space.
- VGA compatible display (1024 x 768 recommended).
- CD-ROM drive.
- Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Robot Lab 3.0
6.5 Robot Lab 3.0
Robot Lab includes a PC software application intended to assist the user in testing robot programs.
Robot Lab includes:
- VirtualRobot application.
VirtualRobot simulates ABB S4 robots on desktop computers. VirtualRobot can be used to test robot programs without having to occupy a real robot system.
The VirtualRobot application consists of three windows: the Teach Pendant, the I/O
Simulator, and the Robot View. The Teach Pendant window simulates the S4 Controller
Teach Pendant, the I/O Simulator window permits user manipulation of digital I/O signals, and the Robot View allows the user to observe the motion of the VirtualRobot as it executes robot programs. The user may choose to run VirtualRobot with or without the I/O Simulator and Robot View.
The VirtualRobot application assumes the functionality of the embedded S4 controller and can be configured with various memory and software options just like a real S4 controller using the Preferences dialog. Configuration includes, for example, the software options available to the controller (ArcWare, SpotWare, Serial RAP, etc.), the robot model (IRB1400H CEILING/DCLinkB, IRB6400C/B-150, etc.), the amount of memory installed in the controller (10MB, 12MB, etc.), and several other parameters.
It should be noted that the VirtualRobot is only available for robot controller versions
2.1 and later. However, it is possible to test many programs for earlier controller versions using VirtualRobot version 2.1.
Robot Lab includes predefined configurations of the controller. The Preferences dialog can be used to select among defined configurations and to create entirely new configurations through user-assisted dialogs or direct import of configuration data from the floppy disks shipped with the robot.
The VirtualRobot I/O Simulator can be used to view and manipulate digital input and output signals during program execution. This feature is useful for testing robot programs that may set outputs or wait on certain input states before continuing. The
VirtualRobot I/O Simulator automatically configures itself with the I/O boards and signals used by the selected robot.
In addition to dynamically displaying robot motion, the Robot View window includes a cycle time clock that displays time computed internally by the robot control system to provide an estimate of cycle time for the real robot.
This estimate does not contain settling time at fine points. By adding 200 ms per fine point, the cycle time accuracy will normally be within ±2 %.
The image below illustrates some features of the Robot View window.
60 Product Specification RobotWare for BaseWare OS 3.1
Cycle Time
Clock controls
Dynamic display of robot in motion
Robot Lab 3.0
Thumbwheels allow user control over 3-D viewing.
PC System Requirements
- Pentium processor.
- 8 MB RAM memory minimum, for Windows 95; 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 100 MB harddisk space.
- VGA compatible display (1024 x 768 recommended).
- CD-ROM drive.
- Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Robot Lab 3.0
62 Product Specification RobotWare for BaseWare OS 3.1
RobComm 3.0
7 FactoryWare
7.1 RobComm 3.0
RobComm is a powerful toolkit for developing PC-based user interfaces for robot systems.
RobComm frees you from the underlying communication protocols, so you spend time designing a user interface, not writing communication software. Typical applications that would make use of RobComm include:
- File servers.
- Cell controllers.
- Statistical process control supervisors.
- Other applications where a graphical operator interface or remote process monitoring and control are desired.
RobComm is a collection of ActiveX Controls (OCXs). The operation of these controls is configured via the control’s properties. RobComm includes three robot-specific
OCXs: the Helper control, the ABB Button control, and the Pilot Light control.
Together they present a flexible, comprehensive communication interface to the S4.
In designing PC user screens, these RobComm controls may be used in combination with Microsoft ActiveX controls and the thousands of other ActiveX controls available from third-party suppliers. In addition, the user application can be tested using the
DeskWare VirtualRobot application (see section 6.5), permitting off-line verification of the operator interface and rapid deployment into production.
The User Application
Designed to leverage industry standard development tools, RobComm supports 32-bit
Windows applications created with Microsoft Visual Basic, Visual C++, or
Wonderware InTouch 7.0. Thus, users benefit from the wide availability of third-party components (known as ActiveX controls) that support these development environments, further reducing development time and effort.
Visual Basic is generally preferred for rapid development of user interface screens, whereas Visual C++ may be needed in complex installations that require integration with other programming libraries.
RobComm is designed such that multiple applications, including multi-threaded applications, can communicate with multiple S4 controllers without conflict.
Applications developed with RobComm will work over a serial line to one robot, or over Ethernet to multiple robots.
Visual Basic source code for two sample applications is included to illustrate the use of RobComm and accelerate the learning curve.
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RobComm 3.0
The two screens shown below, are examples of a Visual Basic application that uses
RobComm to collect and display process statistics, error messages, and robot I/O and to enable remote program modification.
Pilot Light Controls
ABB Button Controls
64 Product Specification RobotWare for BaseWare OS 3.1
RobComm 3.0
Following is a brief description of each ActiveX control included the RobComm toolkit.
The Helper Control
This is the primary communication interface for RobComm. The Helper control is an invisible control that provides methods, properties, and events to expose the entire S4 communication interface.
The ABB Button Control
The ABB Button control is a derivative of the standard Windows button control. An
ABB Button can be connected directly to a specific digital I/O signal in an S4 control.
The Button control provides a simple way to view and modify a digital signal, and, in most cases, can be used without adding code to your application.
The display of the button can be configured via property settings to automatically update itself based on the current state of the communication link to the robot control and the state of the digital signal assigned to the button control. Optionally, you can display bitmaps, text strings, text colors, and/or background colors based on the signal state (on or off). The button action can be configured to turn a signal on, turn a signal off, toggle a signal, pulse a signal, or do nothing in response to a mouse click.
The Pilot Light Control
The Pilot Light control tracks the state of a specific digital signal. This control is configured via properties and requires no additional code.
The display of the Pilot Light is modeled after status lamps commonly used in hardwired operator panels. The Pilot Light displays bitmaps to represent the on and off states of the associated signal. The user selects the on and off colors via properties.
A Caption Property is used to label the Pilot Light.
When the communication link to the robot control is down, the Pilot Light automatically disables itself and re-enables itself when the communication link is restored.
PC System Requirements
- Pentium processor.
- 8 MB RAM memory minimum for Windows 95, 16 MB RAM for Windows
NT (32 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- Microsoft Visual Basic, Visual C++, or Wonderware InTouch 7.0 (for application development).
- 20 MB free hard disk space.
- VGA compatible display (1024 x 768 recommended).
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RobComm 3.0
- CD-ROM drive.
- One or more network interfaces - any NDIS or ODI network adapter (for ethernet) or a serial port (for serial connection to one S4).
- A terminal server with SLIP protocol support is required for connections to multiple S4 controllers not equipped with an ethernet interface.
- Microsoft compatible mouse.
Robot Controller Requirements
- FactoryWare Interface (or RAP communication) installed. FactoryWare Interface is preferred as RAP communication requires run-time licensing on the PC.
- Ethernet interface hardware (optional).
- RobComm 3.0 can be used with all versions of BaseWare OS.
66 Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1
7.2 RobView 3.1
RobView is an end-user application that lets the customer visualise robot data in a PC.
It also lets the user remotely operate robots from a PC and provides access to robot files for simple file transfer and back-up. RobView is Windows-based and easy to use.
RobView comes as a ready to use application and is typically run in a PC on the factory floor, connected to one or more robots. RobView takes care of the PC to robot communication. The user can start working immediately, using the pre-defined features and buttons. He can also define his own buttons and signals.
A built-in user security system can be used to prevent accidental use by unauthorized persons.
Pre-defined controls
In RobView there are several pre-defined objects. They are configured for the user to operate robots, look at various robot status and perform file operations. Each robot is represented by a small robot-box on the screen.
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RobView 3.1
The Robot Box
The ready-made robot-box provides the user with instant information about the most important status of the robot, like Motor power on, Program running and Robot mode. It also allows the user to remotely operate the robot with buttons for Motor Power On/Off,
Load program, Run and Halt the program, and Start from the top of program.
A robot box may also be dragged out of the RobView window and made to float freely on the windows desktop, always visible to the user.
The user can ask for more detailed status by clicking on one of the buttons in the bottom row in the robot-box. He can also start the RobView File manager. The detailed status information that the user can ask for is presented in pre-defined windows as shown below.
Controller Information
A click on the Info button displays the system information. Here the user can see the available buffer space in the robot and information about the robot and its software.
I/O status
A click on the I/O status button displays the digital I/O boards with their input and output signals. The user can select I/O board by clicking on the left and right arrowbuttons at the bottom. The I/O signals are “alive” on the screen and follow the changes in the robot. The user can give the I/O signals his own names - specified for each card and for each robot.
Robot position
A click on the Position button displays the position status. The current position of the robot is displayed as well as the name of the selected tool and work object. The position data is updated as the robot moves.
68 Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1
File manager
When the user clicks on the File manager button in the Robot Box, the RobView File
Manager window is displayed. With the RobView File Manager, maintaining the files in the robots and making back-up copies of programs is simple.
In the RobView File Manager, the user can see both the hierarchy of folders and files on the PC, and the files in the selected robot. This is especially useful for copying files using the familiar Windows “drag-and-drop” interface. The user can copy files and programs back and forth between the robot and the PC without interrupting production.
Files can be renamed and deleted.
Batch operation
In the RobView File Manager there is a Batch menu where the user can make batch files for file-operations that are tedious and repetitive. A batch file can contain Put-,
Get- and Delete-commands. This is useful for example for back-up purposes - a batch file can be started from a user defined button.
User defined controls
In addition to the robot box control that is ready to use, the user can customise
RobView by defining his own views with lamps, signals, command buttons, etc. on the screen and link them to variables or I/O in the robot.
If the user, for example, wants to keep track of a RAPID variable in the robot, for example “PartsProduced”, he just defines it on his screen and it will always be updated and display the correct value. The user can also edit a data field on the PC screen and have the value sent to the robot. In this way the user can prepare and send production data to his robots, e.g. number of parts to produce, type of part, etc., without interrupting production.
The user can build complete screens containing customised views of the production cell, including robots and external equipment with layout-drawings, command buttons, signals and display of data.
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RobView 3.1
The layout drawings of the production-cell are made with a standard drawing program like Windows PaintBrush, or a drawing coming from for example AutoCad. These bitmap drawings are displayed in each view in RobView as a “background” for the robot boxes, buttons, data fields, etc.
The screen is split in two parts: the main part and the project part. The user can design his own controls in both parts of the window. The “main” part of the window contains one view that is active all the time. The “project” part of the window can have up to 32 different “pages” or views (screens), where one is visible at a time. The user can switch between the views by selecting them from a list or at the push of a button (the user can specify which button to press for which view). A view can also be selected automatically, based on a variable or I/O in a robot.
Controls are defined in easy to use dialogue boxes where the user selects how the controls will look on the screen.
The same dialogues (under the Triggers tab) are also used to link the controls to variables in the robot.
Shape
By simple click-and-select, the user can define a rectangle, square, oval, circle, rounded rectangle, etc., set it to be filled or transparent, set the thickness of the border, set the colours, etc. More importantly, the shape can be linked to variables or digital I/O in the robot and made to change its colour, become invisible, etc., dependent on the value in the robot. The shape can even be made to move on the PC screen, dependent on the value of variables in the robot.
Label
A label can be a lot of different things: It can be as simple as plain text on the screen, or it can be an edit field displaying a value from the robot with the ability for the operator to edit the value and send it back to the robot. The user can define labels in any view.
The label can be linked to a variable or digital I/O in the robot to display the value (be that numbers or text) and can also change its fill colour, text colour or become invisible.
The user-input on a label (edit-field) can be protected, so that only qualified users are allowed to change data in the robot.
Command button
A command button can be used for a lot of different things: set or reset I/O’s, clear a value of a variable, start a program, start a file transfer - its up to the imagination of the user.
The user can define command buttons in any view and specify one or more actions that is to occur when the button is operated. Command buttons can be protected, so that only qualified operators are allowed to operate them. A button can have a text and/or a bitmap.
70 Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1
In addition, also a button can be linked to variables or I/O in the robot and made to change its bitmap picture, the colour of the text or become invisible, dependent on the value in the robot.
Grid
A grid can be connected to both complex variables or arrays. It will dynamically updated the data field displaying the value of a robot variable, and has the ability to edit the value and send it back to the robot.
The user can define grids in any view. It is easy to set the size of the grid from the Grid property page. You may also define column and row header texts.
The user-input on a grid can be protected, so that only qualified users are allowed to change data in the robot.
Icon
The icon control is used for drawing a picture on any of the views. The picture files are typically bitmap files (.bmp) or icon (.ico) files that you for example have prepared with the Windows Paint application, or have exported from some other drawing program. The icon can be linked to a variable or digital I/O in the robot and made to change picture or become invisible dependent on the value of the robot variable.
Hot-Spot
Select the Hot-spot control to draw a hot-spot in any of the views. It is usually placed on top of other controls (e.g. Icon), to make RobView change view when you click on the hot-spot. The hot-spot is invisible in run mode.
Peripheral equipment
The user defined controls can also be linked to signals in peripheral equipment. This can be done in two ways: 1) By using spare I/O in the robot where signals from the peripheral equipment are connected so that RobView can reach them or 2) by using a dedicated DDE Server if one is available for the equipment in question, so that
RobView can connect to the variables of that DDE Server and in this way be able to control and monitor the external equipment.
Multiple robots
RobView can be supplied with support for one or multiple robots. For use with one robot, the robot is connected directly to the serial port in the PC.
If the robots are equipped with a network option, they can be connected directly by ethernet to the networked PC.
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RobView 3.1
For use with more than one robot with serial connections, a “terminal server” is needed in the set-up. This is a box with eight or more serial ports and an ethernet port. The robots are connected to the serial ports and the PC (with an ethernet board) to the ethernet port. The “ShivaPort” from Shiva (used to be called “SpiderPort”) is an example of a good terminal server for this use.
PC System Requirements
The requirements for RobView will depend on the size of the installation and the number of robots. The descriptions below are recommendations only.
RobView for one robot
486 DX-66 minimum (Pentium recommended).
16 MB RAM memory or more.
10 MB free harddisk space.
Windows-95 or Windows/NT installed.
VGA compatible display (higher resolution recommended).
3.5” 1.44 MB diskette drive or CD rom.
Serial port or Network board.
RobView for multiple robots
Pentium 75 MHz (minimum).
16 MB RAM memory min. (more recommended).
10 MB free harddisk space.
Windows-95 or Windows/NT installed.
VGA compatible display (higher resolution and large screen strongly recommended).
3.5” 1.44 MB diskette drive or CD rom.
Network board (e.g. 3COM EtherLink III 3C509).
Alternatively a terminal server may be used.
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Robot Controller Requirements
FactoryWare Interface 3.1 (or RAP Communication 3.1) installed.
Ethernet interface hardware (optional).
RobComm 3.1 can run with all versions of BaseWare OS.
Product Specification RobotWare for BaseWare OS 3.1
Technical specification
Platform:
Operating system:
TCP/IP stack:
RPC:
Software protection:
User security:
RobView 3.1
IBM/Intel based PC and compatibles
Microsoft Windows-95 or Windows/NT 4.0
(not included)
The generic Microsoft winsock.dll (not included, comes with Windows)
Public domain Sun rpc.dll, ported to Windows/NT
(included)
Access key, placed in printer port, with keypassword. (Will run for five hour intervals without password or key)
Optional Log In functionality with user-id and user-password. Four user levels: View, Safe,
Expert and “Programmer”
Product Specification RobotWare for BaseWare OS 3.1
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DDE Server 2.3
7.3 DDE Server 2.3
The DDE Server is a software building block that provides reliable, quick and accurate flow of information between robots and a PC. This is what the user needs if he wants to build his own customised user interface, using visualisation packages like for example “InTouch” from Wonderware.
The S4 DDE Server takes care of the communication with the robot, and presents the data in the industry standard DDE communication protocol. DDE stands for Dynamic
Data Exchange. It is a communication protocol designed by Microsoft to allow
Windows applications to send and receive data to/from each other. It is implemented as a client/server mechanism. The server application (like the ABB S4 DDE Server) provides the data and accepts requests from any other application that is interested in its data. An application that can “talk” the DDE “language” can communicate with the
ABB robots via the S4 DDE Server. Examples of applications that do DDE communication are Microsoft “Excel” and “InTouch” from Wonderware.
The S4 DDE Server communicates with robots using the ABB RAP protocol. The S4
DDE Server maintains a database of the relevant variables in the robot and makes sure that these DDE variables are kept updated at all times. The application using the DDE
Server can concentrate on the user interface and rely on the updated DDE variables. If new RAPID variables are introduced in the robot program, the DDE Server is able to create corresponding DDE variables “on-the-fly”.
Functionality
The S4 DDE Server provides reading and writing of I/O, RAPID variables and robot system variables. It supports spontaneous messages from the robot (SCWrite), error messages, as well as file operations. A file batch functionality is also included.
Digital I/O
The user can read or write to the digital I/O signals in the robot. The S4 DDE Server supports both group-I/O and block-I/O transfer. This improves the speed significantly.
RAPID variables
The user can read or write to RAPID variables that are defined and declared as persistent (PERS). The S4 DDE Server supports strings and numbers as well as more complex data types like wobjdata, pos, speeddata and tooldata. The names of the variables are defined by the user.
74 Product Specification RobotWare for BaseWare OS 3.1
DDE Server 2.3
SCWrite
The user can address persistent RAPID variables that are written by the robot to the
DDE Server (using the SCWrite RAPID instruction). The S4 DDE Server supports strings and numbers as well as more complex data types like wobjdata, pos, speeddata and tooldata. The name of the variables are defined by the user.
A superior-computer-write variable is only updated when the SCWrite RAPID instruction is executed in the robot. The user includes the SCWrite instruction at points in his RAPID program where he wants this update to take place.
System variables
With the system variables the user can read various status of the robot controller
(controller ready/executing, program loaded, the position of the robot, etc.). Writing to the system variables will turn the motor power on/off, load a program, run it, etc. The system variables are pre-defined in the S4 DDE Server.
Program variables
With the program variables the user can control the loading and execution of programs in the robot. The variables are pre-defined in the S4 DDE Server.
Error variables
With the error variables the user can read the various error messages generated by the robot. The variables are pre-defined in the S4 DDE Server.
File operations
With the file operation variables the user can perform the following file operations: get file, put file, delete file, rename file, get directory listing and batch operation. These are pre-defined in the S4 DDE Server.
Batch operation
The S4 DDE Server offers a batch facility for file operations. The user can specify several file operations in a batch file (text file) and the DDE Server will execute this file to do multiple file-upload, download, delete, etc. This is a feature that is used for performing repetitive, regular file operations like back-up. A log-file reports how the file operations went.
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DDE Server 2.3
Communication link
The user can read the communication variable to get information about the communication link to the robot. It will tell the user if the robot is up and running and communicating with the PC. It is pre-defined in the S4 DDE Server.
Addressing the DDE variables
You may think of a DDE variable (item) as a placeholder for a variable in the S4 robot controller. An example: To connect a cell in an MS Excel worksheet to a digital output
(ex: do1) in the S4 robot controller, you type:
=ABBS4DDE|ROB1!a_digio_raplong_do1 in the formula bar in Excel, and press enter. From now on the cell in Excel will show a “1” when do1 is on and a “0” when do1 is off.
Multiple robots
The DDE Server can be supplied with support for one or multiple robots. For use with one robot, the robot is connected directly to the serial port in the PC.
If the robots are equipped with a network option, they can be connected directly by ethernet to the networked PC.
For use with more than one robot with serial connections, a “terminal server” is needed in the set-up. This is a box with eight or more serial ports and an ethernet port. The robots are connected to the serial ports and the PC (with an ethernet board) to the ethernet port. The “ShivaPort” from Shiva (used to be called “SpiderPort”) is an example of a good terminal server for this use.
PC System Requirements
The requirements for the DDE Server will depend on the size of the installation and the number of robots. The descriptions below are recommendations only.
DDE Server for one robot
486 DX-66 minimum (Pentium recommended).
16 MB RAM memory or more.
10 MB free harddisk space.
Windows-95 or Windows/NT installed.
VGA compatible display (higher resolution recommended).
3.5” 1.44 MB diskette drive or CD rom.
Serial port or Network board.
76 Product Specification RobotWare for BaseWare OS 3.1
DDE Server 2.3
DDE Server for multiple robots
Pentium 75 MHz (minimum).
16 MB RAM memory min. (more recommended).
10 MB free harddisk space.
Windows-95 or Windows/NT installed.
VGA compatible display (higher resolution and large screen strongly recommended).
3.5” 1.44 MB diskette drive or CD rom.
Network board (e.g. 3COM EtherLink III 3C509)
Alternatively a terminal server may be used.
Robot Controller Requirements
FactoryWare Interface 3.1 (or RAP Communication 3.1) installed.
Ethernet interface hardware (optional).
RobComm 3.1 can run with all versions of BaseWare OS.
Technical specification
Platform: IBM/Intel based PC and compatibles
Operating system: Microsoft Windows-95 or Windows/NT 4.0 (not included)
TCP/IP stack: The generic Microsoft winsock.dll (not included, comes with
Windows)
RPC: Public domain Sun rpc.dll, ported to Windows/NT (included)
Software protection: Access key, placed in printer port, with key-password. (Will run for five hour intervals without password or key)
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ScreenMaker 3.0
7.4 ScreenMaker 3.0
ScreenMaker is a software product that assists the user in creating and editing user screen package files in a PC. See the ScreenViewer option for description of the user screens.
This product offers the advantages of the Windows environment. Some of the main features of ScreenMaker include:
- Easy to edit representation of user screens (using a tree and a list view).
- User friendly modification commands (rename, properties, insert, delete, etc.) via toolbar, shortcuts and mouse right click menu.
- Preview of a screen as it will be displayed on the teach pendant (including the strokes and the fields).
- Gives exact memory size that the screen package takes up when loaded onto the controller.
- Ability to check the syntax of display commands.
- Standard cut, copy and paste functions.
PC System Requirements
- 486 DX-33 minimum (Pentium recommended).
- 8 MB RAM memory minimum for Windows 95, 12 MB RAM for Windows
NT(16 MB RAM recommended).
- Windows 95 or Windows NT 4.0.
- 5 MB free harddisk space.
- VGA compatible display (1024 x 768 recommended).
- Microsoft compatible mouse.
- 3.5" 1.44 MB diskette drive.
78 Product Specification RobotWare for BaseWare OS 3.1
Safety
CONTENTS
Page
7.6 General Mode Safeguarded Stop (GS) connection................................................ 9
7.7 Automatic Mode Safeguarded Stop (AS) connection ........................................... 10
Product Manual 1
Safety
2 Product Manual
Safety
Safety
1 General
This information on safety covers functions that have to do with the operation of the industrial robot.
The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system.
To protect personnel, the complete system has to be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly.
People who work with robots must be familiar with the operation and handling of the industrial robot, described in applicable documents, e.g. Users’s Guide and Product
Manual.
The diskettes which contain the robot’s control programs must not be changed in any way because this could lead to the deactivation of safety functions, such as reduced speed.
1.1 Introduction
Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices.
Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual/Installation, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
2 Applicable Safety Standards
The robot is designed in accordance with the requirements of ISO10218, Jan. 1992,
Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1992 stipulations.
Product Manual 3
Safety
3 Fire-Extinguishing
Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).
4 Definitions of Safety Functions
Emergency stop – IEC 204-1,10.7
A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous functions controlled by the robot.
Enabling device – ISO 11161, 3.4
A manually operated device which, when continuously activated in one position only, allows hazardous functions but does not initiate them. In any other position, hazardous functions can be stopped safely.
Safety stop – ISO 10218 (EN 775), 6.4.3
When a safety stop circuit is provided, each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit. It is necessary to reset the power to the machine actuators before any robot motion can be initiated.
However, if only the power to the machine actuators is reset, this should not suffice to initiate any operation.
Reduced speed – ISO 10218 (EN 775), 3.2.17
A single, selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot.
Interlock (for safeguarding) – ISO 10218 (EN 775), 3.2.8
A function that interconnects a guard(s) or a device(s) and the robot controller and/or power system of the robot and its associated equipment.
Hold-to-run control – ISO 10218 (EN 775), 3.2.7
A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released.
4 Product Manual
Safety
5 Safe Working Procedures
Safe working procedures must be used to prevent injury. No safety device or circuit may be modified, bypassed or changed in any way, at any time.
5.1 Normal operations
All normal operations in automatic mode must be executed from outside the safeguarded space.
6 Programming, Testing and Servicing
The robot is extremely heavy and powerful, even at low speed. When entering into the robot’s safeguarded space, the applicable safety regulations of the country concerned must be observed.
Operators must be aware of the fact that the robot can make unexpected movements.
A pause (stop) in a pattern of movements may be followed by a movement at high speed. Operators must also be aware of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without warning.
If work must be carried out within the robot’s work envelope, the following points must be observed:
• The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.
• The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% – full speed – may only be used by trained personnel who are aware of the risks that this entails.
Do not change “Transm gear ratio” or other kinematic parameters from the teach pendant or a PC. This will affect the safety function Reduced speed
250 mm/s.
• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.
The enabling device must never be rendered inoperative in any way.
• The programmer must always take the teach pendant with him/her when entering through the safety gate to the robot’s working space so that no-one else can take over control of the robot without his/her knowledge.
Product Manual 5
Safety
7 Safety Functions
7.1 The safety control chain of operation
The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode.
Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode. MOTORS
ON mode means that drive power is supplied to the motors.
If any contact in the safety chain of operation is open, the robot always reverts to
MOTORS OFF mode. MOTORS OFF mode means that drive power is removed from the robot’s motors and the brakes are applied.
K1 K2
Drive
Unit
M
K1 K2
Interlocking
EN RUN
& &
LIM1 ES1
Man1
+
GS1
TPU
En1
AS1
Auto1
LIM2 ES2
External contactors
Man2
GS2
TPU
En2
AS2
Auto2
+
The status of the switches is indicated by LEDs on top of the panel module in the control cabinet and is also displayed on the teach pendant (I/O window).
After a stop, the switch must be reset at the unit which caused the stop before the robot can be ordered to start again.
The time limits for the central two channel cyclic supervisions of the safety control chain is between 2 and 4 second.
The safety chains must never be bypassed, modified or changed in any other way.
6 Product Manual
Safety
7.2 Emergency stops
An emergency stop should be activated if there is a danger to people or equipment.
Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the teach pendant.
External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual/Installation). They must be connected in accordance with the applicable standards for emergency stop circuits.
Before commissioning the robot, all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation.
Before switching to MOTORS ON mode again, establish the reason for the stop and rectify the fault.
7.3 Mode selection using the operating mode selector
The applicable safety requirements for using robots, laid down in accordance with
ISO/DIS 10218, are characterised by different modes, selected by means of control devices and with clear-cut positions.
One automatic and two manual modes are available:
Manual mode:
< 250 mm/s - max. speed is 250mm/s
100% - full speed
Automatic mode: The robot can be operated via a remote control device
The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the robot’s safeguarded space. The robot must be operated using the teach pendant and, if
100% is selected, using Hold-to-run control.
In automatic mode, the operating mode selector is switched to , and all safety arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. No-one may enter the robot’s safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space.
Programming and testing at reduced speed
Robot movements at reduced speed can be carried out as follows:
• Set the operating mode selector to <250 mm/s
• Programs can only be started using the teach pendant with the enabling device activated.
The automatic mode safeguarded space stop (AS) function is not active in this mode.
Product Manual 7
Safety
Testing at full speed
Robot movements at programmed speed can be carried out as follows:
• Set the operating mode selector to 100%
• Programs can only be started using the teach pendant with the enabling device activated.
For “Hold-to-run control”, the Hold-to-run button must be activated. Releasing the button stops program execution.
The 100% mode may only be used by trained personnel. The applicable laws and regulations of the countries where the robot is used must always be observed.
Automatic operation
Automatic operation may start when the following conditions are fulfilled:
• The operating mode selector is set to
• The MOTORS ON mode is selected
Either the teach pendant can be used to start the program or a connected remote control device. These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded space.
7.4 Enabling device
When the operating mode selector is in the MANUAL or MANUAL FULL SPEED position, the robot can be set to the MOTORS ON mode by depressing the enabling device on the teach pendant.
Should the robot revert to the MOTORS OFF mode for any reason while the enabling device is depressed, the latter must be released before the robot can be returned to the
MOTORS ON mode again. This is a safety function designed to prevent the enabling device from being rendered inactive.
When the enabling device is released, the drive power to the motors is switched off, the brakes are applied and the robot reverts to the MOTORS OFF mode.
If the enabling device is reactivated, the robot changes to the MOTORS ON mode.
7.5 Hold-to-run control
This function is always active when the operating mode selector is in the MANUAL
FULL SPEED position. It is possible to set a parameter to make this function active also when the operating mode selector is in the MANUAL position.
8 Product Manual
Safety
When the Hold-to-run control is active, the enabling device and the Hold-to-run button on the teach pendant must be depressed in order to execute a program. When the button is released, the axis (axes) movements stop and the robot remains in the MOTORS ON mode.
Here is a detailed description of how to execute a program in Hold-to-run control:
• Activate the enabling device on the teach pendant.
• Choose execution mode using the function keys on the teach pendant:
- Start (continuous running of the program)
- FWD (one instruction forwards)
- BWD (one instruction backwards)
• Wait for the Hold-to-run alert box.
• Activate the Hold-to-run button on the teach pendant.
Now the program will run (with the chosen execution mode) as long as the Hold-torun button is pressed. Releasing the button stops program execution and activating the button will start program execution again.
For FWD and BWD execution modes, the next instruction is run by releasing and activating the Hold-to-run button.
It is possible to change execution mode when the Hold-to-run button is released and then continue the program execution with the new execution mode, by just activating the Hold-to-run button again, i.e. no alert box is shown.
If the program execution was stopped with the Stop button on the teach pendant, the program execution will be continued by releasing and activating the Hold-to-run button.
When the enabling device on the teach pendant is released, the sequence described above must be repeated from the beginning.
7.6 General Mode Safeguarded Stop (GS) connection
The GS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats. The GS is active regardless of the position of the operating mode selector.
When this connection is open the robot changes to the MOTORS OFF mode. To reset to MOTORS ON mode, the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. This is not normally done by resetting the device itself.
Product Manual 9
Safety
7.7 Automatic Mode Safeguarded Stop (AS) connection
The AS connection is provided for interlocking external safety devices, such as light curtains, light beams or sensitive mats used externally by the system builder. The AS is especially intended for use in automatic mode, during normal program execution.
The AS is by-passed when the operating mode selector is in the MANUAL or
MANUAL FULL SPEED position.
7.8 Limiting the working space
For certain applications, movement about the robot’s main axes must be limited in order to create a sufficiently large safety zone. This will reduce the risk of damage to the robot if it collides with external safety arrangements, such as barriers, etc.
Movement about axes 1, 2 and 3 can be limited with adjustable mechanical stops or by means of electrical limit switches. If the working space is limited by means of stops or switches, the corresponding software limitation parameters must also be changed. If necessary, movement of the three wrist axes can also be limited by the computer software. Limitation of movement of the axes must be carried out by the user.
7.9 Supplementary functions
Functions via specific digital inputs:
• A stop can be activated via a connection with a digital input. Digital inputs can be used to stop programs if, for example, a fault occurs in the peripheral equipment.
Functions via specific digital outputs:
• Error – indicates a fault in the robot system.
• Cycle_on – indicates that the robot is executing a program.
• MotOnState/MotOffState – indicates that the robot is in MOTORS ON / MOTORS
OFF mode.
• EmStop - indicates that the robot is in emergency stop state.
• AutoOn - indicates that the robot is in automatic mode.
8 Safety Risks Related to End Effectors
8.1 Gripper
If a gripper is used to hold a workpiece, inadvertent loosening of the workpiece must be prevented.
10 Product Manual
Safety
8.2 Tools/workpieces
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards remain closed until the cutters stop rotating.
Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. It should be possible to release parts by manual operation (valves).
8.3 Pneumatic/hydraulic systems
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy may be present in these systems so, after shutdown, particular 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.
9 Risks during Operation Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.
Remedial action must only ever be carried out by trained personnel who are familiar with the entire installation as well as the special risks associated with its different parts.
The industrial robot is a flexible tool which can be used in many different industrial applications. All work must be carried out professionally and in accordance with applicable safety regulations. Care must be taken at all times.
10 Risks during Installation and Service
To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Special attention must be paid to the following points:
• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.
• The instructions in the Product Manual/Installation must always be followed.
• The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.
Product Manual 11
Safety
• The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
• Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.
• Safety zones, which have to be crossed before admittance, must be set up in front of the robot’s working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator away from the robot’s working space.
• Those in charge of operations must make sure that safety instructions are available for the installation in question.
• Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.
Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.
Even if the power supply for the robot is turned off, you can still injure yourself.
• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the tie rod.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, is dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored energy (DC link) and hot parts in the controller.
• Units inside the controller, e.g. I/O modules, can be supplied with external power.
11 Risks Associated with Live Electric Parts
Controller
A danger of high voltage is associated with the following parts:
- The mains supply/mains switch
- The power unit
- The power supply unit for the computer system (55 V AC)
- The rectifier unit (260 V AC and 370 V DC. NB: Capacitors!)
- The drive unit (370 V DC)
- The service outlets (115/230 VAC)
- The power supply unit for tools, or special power supply units for the machining process
12 Product Manual
Safety
- The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.
- Additional connections
Manipulator
A danger of high voltage is associated with the manipulator in:
- The power supply for the motors (up to 370 V DC)
- The user connections for tools or other parts of the installation (see Installation, max. 230 V AC)
Tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in the
OFF position. Power supply cables which are in motion during the working process may be damaged.
12 Emergency Release of Mechanical Arm
If an emergency situation occur where a person is caught by the mechanical robot arm, the brake release buttons should be pressed whereby the arms can be moved to release the person. To move the arms by manpower is normally possible on the smaller robots
(1400 and 2400), but for the bigger ones it might not be possible without a mechanical lifting device, like an overhead crane.
If power is not available the brakes are applied, and therefore manpower might not be sufficient for any robot.
Before releasing the brakes, secure that the weight of the arms not enhance the press force on the caught person.
13 Limitation of Liability
The above information regarding safety must not be construed as a warranty by
ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with.
14 Related Information
Installation of safety devices
Changing robot modes
Limiting the working space
Product Manual
Described in:
Product Manual - Installation and
Commissioning
User’s Guide - Starting up
Product Manual - Installation and
Commissioning
13
Safety
14 Product Manual
To the User
“Declaration by the manufacturer”.
This is only a translation of the customs declaration. The original document (in English) with the serial number on it is supplied together with the robot
Declaration by the manufacturer as defined by machinery directive 89/392/EEC Annex II B
Herewith we declare that the industrial robot
IRB 1400
IRB 4400
IRB 2000
IRB 6000
IRB 2400
IRB 6400
IRB 3000
IRB 6400C manufactured by ABB Robotics Products AB 721 68 Västerås, Sweden with serial No.
Label with serial number
IRB 3400
IRB 640 is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the directive, 91/368 EEC.
Applied harmonised standards in particular:
EN 292-1
EN 292-2
EN 418
EN 563
EN 614-1
EN 775
EN 60204 prEN 574 prEN 953 prEN 954-1
EN 50081-2
EN 55011 Class A
EN 55011 Class A
EN 50082-2
EN 61000-4-2
EN 61000-4-3
ENV 50204
EN 61000-4-4
ENV 50141
Safety of machinery, basic terminology
Safety of machinery, technical principles/specifications, emergency stop
Safety of machinery, emergency stop equipment
Safety of machinery, temperatures of surfaces
Safety of machiney, ergonomic design principles
Robot safety
Electrical equipment for industrial machines
Safety of machinery, two-hand control device
Safety of machinery, fixed / moveable guards
Safety of machinery, safety related parts of the control system
Radiated emission enclosure
ORMA
Conducted emission AC Mains
EMC, Generic immunity standard. Part 2: Industrial environment
Electrostatic discharge immunity test
Y
F
OR
Radiated, radio-frequency, electromagnetic field immunity yest
Radeated electromagnetic field from digital radio telephones, immunity test
Electrical fast transient/burst immunity test
ONL
TI
O
N
Prepared
M Jonsson, 970904
Approved by,date
K-G Ramström, 970905
Product Design Responsible
Status
APPROVED
Responsible department
SEROP/K
Take over department
ABB Robotics Products
Title
Declaration by the manuf.
Technical Provisions
Tillverkardeklaration
Document No
3HAB 3585-1
Page
1
No.of pages
1
Rev. ind.
08
ABB ROBOTICS PRODUCTS AB
Robot type:
For RAC:
Revision:
RAC Ref no:
Date
CONFIGURATION LIST
Manufact order no: Serial no:
Sales order no:
Name Tested and approved:
MANIPULATOR:
QTY system delivered regarding configuration and extent.
Date
Delivery to customer:
Acceptance by customer:
Customer information:
Customer:
Address:
OPTION/PARTNO
OPTIONS/DOCUMENTATION
REVISION DESCRIPTION
System Description
CONTENTS
Page
5.2 MOTORS ON and MOTORS OFF modes............................................................. 18
Product Manual 1
System Description
CONTENTS
Page
2 Product Manual
System Description Structure
1 Structure
The robot is made up of two main parts, manipulator and controller, described in sec-
1.1 Manipulator
It is equipped with maintenance-free, AC motors which have electromechanical brakes. The brakes lock the motors when the robot is inoperative for more than 1000 hours. The time is configurabble for the user.
The following figures shows the various ways in which the different manipulators moves and its component parts.
Motor axis 5
Motor axis 6
Axis 3
Axis 4 Axis 5
Axis 6
Motor axis 4
Upper arm
Motor axis 1
Axis 2 Lower arm
Motor axis 2
Motor axis 3
Axis 1
Product Manual
Base
Figure 1 The motion patterns of the IRB 1400 and IRB 140.
3
Structure
4
System Description
Motor unit axis 4
Motor unit axis 5
Motor unit axis 6
Axis 4
Axis 3
Upper arm
Motor unit and gearbox axis 1
Motor unit and gearbox axis 3
Figure 2 The motion patterns of the IRB 2400.
Axis 5
Upper arm
Axis 4
Axis 6
Axis 5
Lower arm
Axis 2
Motor unit and gearbox axis 2
Axis 1
Base
Motor axis 4
Motor axis 5
Motor axis 6
Axis 6
Axis 3
Lower arm
Axis 2
Motor axis 1
Motor axis 3
Axis 1
Figure 3 The motion patterns of the IRB 4400.
Motor axis 2
Base
Product Manual
System Description Structure
Motor axis 4
Motor axis 1
Motor axis 3
Axis 3
Upper arm
Motor axis 5
Axis 4
Axis 5
Motor axis 6
Axis 6
Axis 2
Motor axis 2
Lower arm
Axis 1
Figure 4 The motion patterns of the IRB 6400.
Upper arm
Axis 3
Base
Motor axis 6
Motor axis 3
Motor axis 1
Axis 2
Axis 6
Motor axis 2
Lower arm
Axis 1
Product Manual
Figure 5 The motion patterns of the IRB 640.
5
Structure
Motor 1(X)-axis
Motor 2(Y)-axis
2(Y)-axis
Motor 3(Z)-axis
System Description
Motor 4(C)-axis
3(Z)-axis
4(C)-axis
1(X)-axis
Figure 6 The motion patterns of the IRB 840/A.
6 Product Manual
System Description Structure
1.2 Controller
The controller, which contains the electronics used to control the manipulator and peripheral equipment, is specifically designed for robot control, and consequently provides optimal performance and functionality.
Figure 7 shows the location of the various components on the cabinet.
Mains switch
Teach pendant
Operator’s panel
Disk drive
Manipulator connection
Figure 7 The exterior of the cabinet showing the location of the various units.
Product Manual 7
Structure System Description
1.3 Electronics unit
All control and supervisory electronics, apart from the serial measurement board, which is located inside the manipulator, are gathered together inside the controller.
Supply unit
Transformer
8
Figure 8 The location of the electronics boards and units behind the front door.
The computer unit (supply unit + board backplane) comprises the following parts:
• Robot computer board – contains computers used to control the manipulator motion and I/O communication.
• Memory board – contains extra RAM memory, there are three sizes, 8 and 16 MB.
• Main computer board – contains 8 MB RAM memory and the main computer, which controls the entire robot system.
• Optional boards-
Communication boards, containing circuits for network and field bus communication.
• Supply unit–
4 regulated and short-circuit-protected output voltages.
Drive system:
• DC link– converts a three-phase AC voltage to a DC voltage.
• Drive module – controls the torque of 2-3 motors.
When the maximum capacity for external axes is utilized, a second control cabinet is used. The external axes cabinet comprises AC connection, main switch, contactors, transformer, DC-link, drive module(s), and supply unit, but no computer unit.
Product Manual
System Description Structure
I/O units (x4)
AC connection
Lithium batteries
Panel unit
Motors On and brake contactors
Floppy disk
Figure 9 The location of units under the top cover.
• Lithium batteries for memory back-up.
• Panel unit – gathers and coordinates all signals that affect operational and personal safety.
• I/O units – enables communication with external equipment by means of digital inputs and outputs, analog signals or field buses.
I/O units can alternatively be located outside the cabinet. Communication with robot data is implemented via a stranded wire CAN bus, which allows the units to be positioned close to the process.
• Serial measurement board (in the manipulator) – gathers resolver data and transfers it serially to the robot computer board. The serial measurement board is battery-backed so that the revolution information cannot be lost during a power failure.
Product Manual 9
Structure System Description
10 Product Manual
System Description Computer System
2 Computer System
The computer system is made up of three computers on two circuit boards. The computers comprise:
- Main computer board – contains the main computer of the robot and controls the entire robot.
- Robot computer board – contains the I/O computer which acts as a link between the main computer, the world around and the axis computer that regulates the velocity of the robot axes.
To find out where the various boards are located, see Electronics unit on page 8.
The computers are the data processing centre of the robot. They possess all the functions required to create, execute and store a robot program. They also contain func-
tions for coordinating and regulating the axis movements. Figure 10 shows how the
computer system communicates with the other units.
Main computer board
Main computer
Memory board
Robot computer board
Axis computer I/O computer
Network I/O computer
Teach pendant
Drive units
Serial measurement board Disk drive
Figure 10 The interfaces of the computer system.
I/O units
Product Manual 11
Computer System System Description
12 Product Manual
System Description Servo System
3 Servo System
3.1 Principle function
The servo system is a complex system comprising several different interacting units and system parts – both hardware and software. The servo function comprises:
• Digital regulation of the poses, velocity and motor current of the robot axes.
• Synchronous AC operation of the robot motors.
3.2 Regulation
During execution, new data on the poses of the robot axes is continuously received from the serial measurement board. This data is input into the position regulator and then compared with previous position data. After it has been compared and amplified, new references are given for the pose and velocity of the robot.
The system also contains a model of the robot which continuously calculates the optimal regulator parameters for the gravitation, the moment of inertia and the interaction
3.3 Controlling the robot
An digital current reference for two phases is calculated on the basis of the resolver signal and a known relationship between the resolver angle and rotor angle. The third phase is created from the other two.
The current of the phases is regulated in the drive unit in separate current regulators. In this way, three voltage references are returned which, by pulse-modulating the rectifier voltage, are amplified to the working voltage of the motors.
The serial measurement board receives resolver data from a maximum of six resolvers and generates information on the position of the resolvers.
Product Manual 13
Servo System System Description
The following diagrams outline the system structure for AC operation as well as the fundamental structure of the drive unit.
Rotor position
Computer
Torque reference
Serial measurement board
DC link
Drive Unit M R
AC OPERATION
DC link
TORQUE reference
ROTOR
POSITION
CURRENT
ESTIMATOR
+
-
+ -
CURRENT
REGULATOR
+
PWM
-
+
PWM
PWM
-
+
-
MAIN
CIRCUITS
U
W
M
V
Figure 11 System structure for AC operation.
3.4 Overload protection
PTC resistance is built into the robot motors to provide thermal protection against overloads. The PTC sensors are connected to an input on the panel unit which is sensitive to resistance level and which check that low resistance is maintained.
The robot computer checks the motors for overloading at regular intervals by reading the panel unit register. In the event of an overload, all motors are switched off.
14 Product Manual
System Description I/O System
4 I/O System
Communicates with other equipment using digital and analog input and output signals.
VME bus
Main computer
I/O computer
Teach pendant
Disk drive
General
Serial ports
RS 422
RS 232
SIO2
SIO1
Distributed
I/O bus
CAN/
DeviceNet
Customer connections
16
16
I/O I/O I/O
Safety signals
Ethernet
I/O unit(s)
Field bus slave unit(s)
Panel unit
Communication board
Product Manual
Figure 12 Overview of the I/O system.
15
I/O System System Description
16 Product Manual
System Description Safety System
5 Safety System
The robot’s safety system is based on a two-channel safety circuit that is continuously monitored. If an error is detected, the power supply to the motors is switched off and the brakes engage. To return the robot to MOTORS ON mode, the two identical chains of switches must be closed. As long as these two chains differ, the robot will remain in the
MOTORS OFF mode.
Figure 13 below illustrates an outline principal circuit with available customer contacts.
LS Solid state switches
Contactor
ES
2nd chain interlock
GS
Drive unit
&
TPU En
M
AS
EN RUN
Computer commands
Auto
Operating mode selector
Manual
AS = Automatic mode safeguarded space Stop
TPU En= Enabling device, teach pendant unit
GS = General mode safeguarded space Stop
ES = Emergency Stop
Figure 13 Outline diagram of one of the safety circuits.
5.1 The chain of operation
The emergency stop buttons on the operator’s panel and on the teach pendant and external emergency stop buttons are included in the two-channel chain of operation.
A safeguarded stop, AUTO STOP, which is active in the AUTO operating mode, can be connected by the user. In any of the MANUAL modes, the enabling device on the teach pendant overrides the AUTO STOP.
The safeguarded stop GENERAL STOP is active in all operating modes and is connected by the user.
The aim of these safeguarded stop functions is to make the area around the manipulator safe while still being able to access it for maintenance and programming.
Product Manual 17
Safety System System Description
If any of the dual switches in the safety circuit are opened, the circuit breaks, the motor contactors drop out, and the robot is stopped by the brakes. If the safety circuit breaks, an interrupt call is sent directly from the panel unit to the robot computer to ensure that the cause of the interrupt is indicated.
When the robot is stopped by a limit switch, it can be moved from this position by jogging it with the joystick while pressing the MOTORS ON button. The MOTORS ON button is monitored and may be depressed for a maximum of 30 seconds.
LEDs for ES, AS and GS are connected to the two safety circuits to enable quick location of the position where the safety chain is broken. The LEDs are located on the upper part of the panel unit. Status indication is also available on the teach pendant display.
5.2 MOTORS ON and MOTORS OFF modes
The principle task of the safety circuit is to ensure that the robot goes into MOTORS
OFF mode as soon as any part of the chain is broken. The robot computer itself controls the last switches (ENABLE and MOTORS ON).
In AUTO mode, you can switch the robot back on by pressing the MOTORS ON button on the operator’s panel. If the circuit is OK, the robot computer then closes the MOTORS ON relay to complete the circuit. When switching to MANUAL, the mode changes to
MOTORS OFF, at which stage the robot computer also opens the MOTORS ON relay. If the robot mode does not change to MOTORS OFF, the ENABLE chain will break and the
ENABLE relay is opened. The safety circuit can thus be broken in two places by the robot computer.
In any of the MANUAL modes, you can start operating again by pressing the enabling device on the teach pendant. If the circuit is OK, the robot computer then closes the
MOTORS ON relay to complete the circuit. The function of the safety circuit can be described as a combination of mechanical switches and robot computer controlled relays which are all continuously monitored by the robot computer.
5.3 Safety stop signals
According to the safety standard ISO/DIS 11161 “Industrial automation systems - safety of integrated manufacturing systems - Basic requirements”, there are two categories of safety stops, category 0 and category 1, see below:
18
The category 0 stop is to be used for safety analysis purposes, when the power supply to the motors must be switched off immediately, such as when a light curtain, used to protect against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop.
Category 1 is preferred for safety analysis purposes, if it is acceptable, such as when gates are used to protect against entry into the work cell. This controlled motion stop takes place within the programmed path, which makes restarting easier.
All the robot’s safety stops are category 0 stops as default.
Safety stops of category 1 can be obtained by activating the soft stop (delayed stop) together with AS or GS. Activation is made by setting a parameter, see User’s Guide, section System Parameters, Topic: Controller.
Product Manual
System Description Safety System
5.4 Limitation of velocity
To program the robot, the operating mode switch must be turned to MANUAL
REDUCED SPEED position. Then the robot’s maximum velocity is limited to 250 mm/s.
5.5 ENABLE
ENABLE is a 24 V signal, generated in the supply unit. The signal is sent through the robot computer, to the panel unit.
The errors that affect the Enable signal are:
• In the supply unit; errors in the input voltage.
• In the robot computer; errors in the diagnostics or servo control program.
• In the drive unit; regulating errors and overcurrent.
5.6 24 V supervision
If the 24 V supply to the safety circuits drops out, the MOTORS ON contactors will drop out, causing the motors to switch off.
5.7 Monitoring
Monitoring is carried out using both hardware and software, and comprises the external part of the safety circuits, including switches and operating contacts. The hardware and software parts operate independently of each other.
The following errors may be detected:
All inputs from the safety circuits are linked to registers, which allows the robot computer to monitor the status. If an interrupt occurs in the circuit, the status can be read.
If any of the switch functions are incorrectly adjusted, causing only one of the chains of operation to be interrupted, the robot computer will detect this. By means of hardware interlocking it is not possible to enter MOTORS ON without correcting the cause.
Product Manual 19
Safety System System Description
20 Product Manual
System Description External Axes
6 External Axes
External axes are controlled by drive units, mounted either inside the controller or out-
side in a separate enclosure, see Figure 14.
The maximum of drive units mounted inside the controller is one or two, depending on robot type.
In addition to drive units from ABB, it is also possible to communicate with external drive units from other vendors. See Product Specification RobotWare for BaseWare
OS 3.1.
Not supplied on delivery
Alt.
Contains no CPU
Measurement System 2
Drive System
1, inside robot cabinet
IRB
Drive System 2 inside external axes cabinet
Measurement
System 1
Not supplied on delivery
Figure 14 Outline diagram, external axes.
Product Manual 21
External Axes System Description
22 Product Manual
Installation and Commissioning
CONTENTS
Page
2. 2 Turning the manipulator (inverted suspension application) .................................. 8
Product Manual IRB 2400 1
Installation and Commissioning
CONTENTS
Page
3.8 The MOTORS ON / MOTORS OFF circuit .......................................................... 49
3.15.1 Connections on upper arm, IRB 2400/10, /16 ........................................... 59
3.15.2 Connections on upper arm, IRB 2400L ..................................................... 60
3.15.3 Connection of signal lamp on upper arm (option) ..................................... 61
3.16.3 Connection and address keying of the CAN-bus....................................... 62
3.16.5 AD Combi I/O DSQC 327 (optional) ........................................................ 67
2 Product Manual IRB 2400
Installation and Commissioning
CONTENTS
Page
3.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC
3.18.2 Ethernet communication, DSQC 336......................................................... 92
Product Manual IRB 2400 3
Installation and Commissioning
CONTENTS
Page
4 Product Manual IRB 2400
Installation and Commissioning Transporting and Unpacking
1 Transporting and Unpacking
NB:
Before starting to unpack and install the robot, read the safety regulations and other instructions very carefully. These are found in separate sections in the
User’s Guide and Product manual.
The installation shall be made by qualified installation personnel and should conform to all national and local codes.
When you have unpacked the robot, check that it has not been damaged during transport or while unpacking.
Operating conditions:
Ambient temperature +5° to +50 ° C (manipulator)
+5° to + 52° C (controller)
Relative humidity Max. 95% at constant temperature
Storage conditions:
If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25°C and +55°C.
When air transport is used, the robot must be located in a pressure-equalized area.
The net weight of the manipulator is approximately: 380 kg
The control system weighs approximately: 240 kg.
Whenever the manipulator is transported, axis 2 must be bent backwards 30° and axis
3 must be moved down to a position against the rubber stops on axis 2.
1.1 Stability / risk of tipping
When the manipulator is not fastened to the floor and standing still, the manipulator is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the manipulator to tip over.
1.2 System diskettes
The diskettes in the box, fixed to the shelf for the teach pendant, should be copied (in a PC) before they are used. Never work with the original diskettes. When you have made copies, store the originals in a safe place.
Do not store diskettes inside the controller due to the high temperatures there.
Product Manual IRB 2400 5
Transporting and Unpacking Installation and Commissioning
6 Product Manual IRB 2400
Installation and Commissioning
2 On-Site Installation
On-Site Installation
2.1 Lifting the manipulator
The best way to lift the manipulator is to use lifting straps and a traverse crane.
tions of the arms, see Chapter 2.7 Manually engaging the brakes. The lifting strap
dimensions must comply with the applicable standards for lifting. See also chapter
2. 2 Turning the manipulator (inverted suspension application) .
Never walk under a suspended load.
Recommended lifting sling:
Type: KDBK 7-8
L=2 m
Load at 90 o
= 380 kg
Move the lower arm backwards approx. 14 o to get balance.
14°
Figure 1 Lifting the manipulator using a traverse crane.
Product Manual IRB 2400 7
On-Site Installation Installation and Commissioning
Use the lifting devices on the cabinet or a fork lift when lifting the controller
If the controller is supplied without its top cover, lifting devices must not be used. A fork lift truck must be used instead.
Min. 60°
A
A
A - A
Figure 2 The maximum angle between the lifting straps when lifting the controller.
2. 2 Turning the manipulator (inverted suspension application)
A special tool is recommended when the manipulator is to be turned for inverted mounting (ABB article number 3HAB 8961-1).
When the special tool is mounted, the manipulator should be positioned according to
Figure 3. The manipulator is delivered in this position.
8 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
Lifting beam min. 960 appr. 520
63 Nm
63 Nm appr. R=1090
65 o
135 o
Figure 3 Manipulator with mounted turning tool.
Fork lift appr. R=1090
Product Manual IRB 2400 9
On-Site Installation
2. 3 Assembling the robot
Installation and Commissioning
2.3.1 Manipulator
The manipulator must be mounted on a level surface with the same hole layout as shown in
Figure 4. The levelness requirement of the surface is as follows:
0.5
Use M16 (x3) screws to bolt the manipulator down (tightening torque 190 Nm, oiled screws).
Two guide sleeves (art.no. 2151 0024-169) can be added to the rear bolt holes, to allow the same robot to be re-mounted without program adjustment.
X
D=18,5
Z = centre line axis 1
D=18,5 (2x)
Y
Z
A
48
20
D=35
+0.039
-0 H8 (2X)
A 0.25
The same dimensions Section A - A
260 260
View from the bottom of the base (footprint)
Figure 4 Bolting down the manipulator.
Note that washers must be used!
Suitable washers: D= 17 / 30 , T= 3 mm
When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the
stress loads defined in Chapter 2.5 Stress forces .
10 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.3.2 Controller
Secure the controller to the floor using M12 screws (as shown in the hole layout below).
See also Chapter 2.6 Amount of space required, before assembling the controller.
720
2.4 Suspended mounting
The method for mounting the manipulator in a suspended position is basically the same as for floor mounting.
There are two holes in the bottom plate which must be sealed with plastic plugs, part no. 2522 2101-9. This applies only to suspended configuration.
If the robot is converted from suspended to floor-mounted configuration, remove the plugs. (They are supplied loose together with the robot for floor-mounting).
Figure 5 Conversion of robot from floor-mounted to suspended configuration.
With inverted installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved.
Product Manual IRB 2400 11
On-Site Installation Installation and Commissioning
2.5 Stress forces
2.5.1 Stiffness
The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot. For optimal performance the frequency of the foundation with the robot weight must be higher than 30 Hz.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
2.5.2 IRB 2400/10, /16
Force xy
Force z, standing
Force z, suspended
Torque xy
Endurance load
(In operation)
± 2000 N
4100 ± 1400 N
- 4100 ± 1400 N
± 3400 Nm
Max. load
(Emergency stop)
± 2600 N
4100 ± 1900 N
- 4100 ± 1900 N
± 4000 Nm
Torque z ± 550 Nm ± 900 Nm
Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 6)
2.5.3 IRB 2400L
Force xy
Force z, standing
Endurance load
(In operation)
± 1700 N
4100 ± 1100 N
Max. load
(Emergency stop)
± 2100 N
4100 ± 1400 N
Force z, suspended - 4100 ± 1100 N
Torque xy ± 3000 Nm
Torque z ± 450 Nm
- 4100 ± 1400 N
± 3400 Nm
± 900 Nm
Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 6)
12 Product Manual IRB 2400
Installation and Commissioning
.
On-Site Installation
X
Z
Figure 6 The directions of the stress forces.
2.6 Amount of space required
The amount of working space required (same for both floor and inverted mounted) to oper-
ate the manipulator and controller is illustrated in Figure 7, Figure 8 and Figure 9.
The working range for axis 1 is +/- 180°.
NB: There are no software or mechanical limits for the working space under the base level of the manipulator.
Product Manual IRB 2400 13
On-Site Installation
2.6.1 Manipulator
Installation and Commissioning
3421
2885
1702
560
Figure 7 The amount of working space required for IRB 2400L.
1810
1189
14 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2900
274
2458
1441
393
Figure 8 The amount of working space required for IRB 2400/10, /16.
1550
1002
Product Manual IRB 2400 15
On-Site Installation
2.6.2 Controller
50
540
Installation and Commissioning
800
Cabinet extension
Option 115
250
200
800
Extended cover
Option 114
950
980 *
Lifting points for forklift * Castor wheels
Figure 9 The amount of space required for the controller.
500
500
16 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.7 Manually engaging the brakes
All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable engagement of the brakes. The voltage supply should be connected to the contact at the base of the manipulator or to the Burndy contact in the base under the
cover if, option 640 is chosen (see Figure 10).
+24 V B8
0 V C10
NOTE!
Be careful not to interchange the
24 V- and 0 V pins.
In they are mixed up, damage can be caused to a resistor and the system board.
Burndy contact: R1.MP4-6
1
4
2
5
3
6 0 V
7
8 9
10 11 12
1
+ 24 V DC
13 14 15
Figure 10 Connection of external voltage to enable engagement of the brakes.
External power must be connected according to Figure 10. Incorrectly connected
power can release all brakes, causing simultaneously movement of all axes.
When the controller or the voltage device is connected as illustrated above, the brakes can be engaged separately using the push-buttons on the connection plate at the rear of the base.
The push-buttons are marked with the appropriate axis name. The names of the axes and
their motion patterns are shown in Figure 11.
Product Manual IRB 2400 17
On-Site Installation Installation and Commissioning
WARNING: Be very careful when engaging the brakes. The axes become activated very quickly and may cause damage or injury.
Axis 4
Axis 5
Axis 3
Axis 6
Axis 2
Axis 1
Figure 11 The robot axes and motion patterns.
2.8 Restricting the working space
When installing the manipulator, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited mechanically for axes 2 and 3 with extra stop lugs and axis 3 with limit switches, and also by using software.
Special kits for limitation of the working space can be ordered. Installation of extra stops for the main axes 1 and 2 and installation of switches on axis 3 is described below.
Limiting the working space using software is described in the System Parameters in the User’s
Guide.
2.8.1 Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the
CAUTION! The original stop pin must not be removed under any circumstances.
18 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
Item Qty Article No.
1 2 3HAB 7310-1
2
3
4
4
9ADA 312-9
9ADA 183-65
Name
Stop axis 1, removable
Dimension
Plain washer 13x24x2.5
Hex socket head cap screw M12x30 8.8
Figure 12 Location of extra stop lugs.
When drilling holes for extra stop lugs, see Figure 13.
Product Manual IRB 2400 19
On-Site Installation Installation and Commissioning
NOTE 1
Only this mounting direction.
NOTE 2
Make a copy and cut out the drilling pattern (Figure 14) and use it to mark out the loca-
tion of the two holes on each stop. Drill the holes through, 10.2, cut threads, M12.
Mount the stops without thightening the screws. Turn axis 1 manually and check the working range between the stops. If necessary correct the angle of impact.
Tighten the screws.
Note 2
Note 1
Max. working range
Note 1
20
Min. working range
Drilling not allowed inside this sector
Center lines for the hidden stiffening ribs
Figure 13 Where to drill the holes for the extra stop lugs.
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
R 264 mm
Scale 1:1
∅
10.2 (x2)
32
60
Figure 14 Drilling pattern.
Product Manual IRB 2400 21
On-Site Installation Installation and Commissioning
2.8.2 Axis 2
The range of rotation for axis 2 can be limited mechanically by fitting extra stop lugs on
Figure 15 Mechanically limiting axis 2.
22 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
Number of parts needed for different angles are shown in the table below:
Working range
+110 o
/ -100 o
+110 o
/ -70 o
+110 o
/ -40 o
+80 o
/ -100 o
+80 o
/ -70 o
+80 o
/ -40 o
+50 o
/ -100 o
+50 o
/ -70 o
+50 o
/ -40 o
+20 o
/ -100 o
+20 o
/ -70 o
+20 o
/ -40 o
1 2 3
-
1
2
1
2
3
2
3
4
3
4
5
Qty
-
2
2
2
2
2
2
2
2
2
2
2
-
2
4
2
4
6
4
6
8
6
8
10
Product Manual IRB 2400 23
On-Site Installation Installation and Commissioning
2.8.3 Axis 3
The working range of axis 3 can be limited by fitting an electric switch on the gear box
axis 3, which senses the position via a cam, see Figure 16.
24
Figure 16 Mounting of electrical stop axis 3.
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.9 Unlimited working range axis 4
N.B. Only valid for IRB 2400/10, /16
The function “Resetting the work area for an axis”, included in Advanced motions 3.0, can also be used for axis 4. To enable useage of this function, the mechanical stop on axis 4 should be removed. Follow the procedure below to dismantle the mechanical stop. See also Foldout 7 in Spare Parts List.
1 Loosen the four screws <32> and dismantle the cover.
2 Slowly rotate axis 4 until the damper <30> is visible through the hole.
3 Remove the damper.
4 Remount the cover and tighten the screws with 15 Nm.
Note that when the damper is removed, axis 4 does not have a mechanical stop. If the robot is provided with cabling on the upper arm, e.g. option 04y, the cabling can be damaged when the function “Resetting the work area for an axis” is used, or if the robot is jogged uncalibrated.
Product Manual IRB 2400 25
On-Site Installation Installation and Commissioning
2.10 Mounting holes for equipment on the manipulator
NB: Never drill a hole in the manipulator without first consulting ABB Flexible
Automation.
IRB 2400/10 and IRB 2400/16
85 110 463 65 177
M6 (2x)
IRB 2400L
Depth of tread 14
M8 (3x)
M5 (2x)
Depth 6
70 65
37
26
M8 (2x)
Depth 14
135 150
Figure 17 Holes for extra equipment, IRB 2400 (Dimensions in mm)
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
M8 (3x) depth 16
R = 77
120 o
120 o
M8 (3x) depth 16
R = 92
120 o
120 o
38 o
IRB 2400/10 and IRB 2400/16
M5 (2x)
22
78
43
IRB 2400L
90
38 o
82
Figure 18 Holes for extra equipment, IRB 2400 (Dimensions in mm)
If the option 623 is mounted, this option occupies the holes on the gearbox axis 3 side.
Product Manual IRB 2400 27
On-Site Installation Installation and Commissioning
.
R=20
45 o
A +0.012
D=6 H7
∅
0.05
B
M6 (4x)
9
B
+0 -0
6
0 o
5x
A
90 o (4x)
6
A - A
Figure 19 The mechanical interface of IRB 2400L (mounting flange).
A
30 o
D=6
+0.012
-0
H7
0.05 B
M6 (6x)
R=25
8
The hole can go through
B
+0.039 -0
+0 -
A
7
A A
Figure 20 The mechanical interface of IRB 2400/10 and IRB 2400/16 (mounting flange).
2.11 Loads
Regarding load diagram, permitted extra loads (equipment) and location of extra loads
(equipment), see chapter 3.4 in Product Specification IRB 2400 (Technical specification). The loads must also be defined in the soft ware, see User´s Guide.
28 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.12 Connecting the controller to the manipulator
Two cables are used to connect the controller to the manipulator, one for measuring signals and the other for motor and brakes.
The connection on the manipulator is located on the rear of the robot base.
2.12.1 Connection on left-hand side of cabinet
The cables are connected to the left side of the cabinet using an industrial connector
and a Burndy connector (see Figure 21). A connector is designated XP when it has
pins (male) and XS when it has sockets (female). A screwed connection is designated
XT.
Motor cable, XP1
XS1
XS2
Measurement cable, XP2
Figure 21 Connections on the cabinet wall.
2.13 Dimensioning the safety fence
A safety fence must be fitted around the robot to ensure a safe robot installation. The fence must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. The maximum speed is determined from the max. velocities of the robot axes and from the position at which the robot is working in the workcell. See Product Specification, section 3.8. The max. speed for a load mounted on the IRB 2400 is 7 m/s.
Applicable standards are ISO/DIS 11161 (see also chapter 3.13) and prEN 999:1995.
Product Manual IRB 2400 29
On-Site Installation Installation and Commissioning
2.14 Mains power connection
Before starting to connect the mains, make sure that the other end of the cable is disconnected from the line voltage.
The power supply can be connected either inside the cabinet, or to a optional socket on the left-hand side of the cabinet or the lower section of the front. The cable connector is supplied but not the cable. The mains supply cables and fuses should be dimensioned in accordance with rated power and line voltage, see rating plate on the controller.
2.14.1 Connection to the mains switch
A gland for the mains cable is located on the left cabinet wall. Pull the mains cable
through the gland (see Figure 22).
PE
30
Cable gland
Connector
Figure 22 Mains connection inside the cabinet.
Connect as below (also see chapter 11, Circuit Diagram.):
1. Release the connector from the knob by depressing the red button located on the upper
side of the connector (see Figure 22).
2. Connect phase 1 to L1 (N.B. Not dependent on phase sequence)
2 to L2
3 to L3
0 to XT26.N(zero is needed only for option 432) and protective earth to
NOTE!
Max. conductor size is 6 mm
2
(AWG 10). Tighten torque 2.3-2.5 Nm.
Retighten after approx. 1 week.
3. Snap the breaker on to the knob again and check that it is fixed properly in the right position.
4. Tighten the cable gland.
5. Fasten the cover plate.
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.14.2 Connection via a power socket
You can also connect the mains supply via an optional wall socket of type CEE 3x16 and
3x32 A, or via an industrial Harting connector (DIN 41 640). See Figure 23.
Cable connectors are supplied (option 133 - 134).
CEE connector DIN connector
Figure 23 Mains connection via an optional wall socket.
2.15 Inspection before start-up
Before switching on the power supply, check that the following have been performed:
1. The robot has been properly mechanically mounted and is stable
2. The controller mains section is protected with fuses.
3. The electrical connections are correct and corresponds to the identification plate on the controller.
4. The teach pendant and peripheral equippment are properly connected.
5. That limiting devices that establish the restricted space (when utilized) are installed.
6. The physical environment is as specified.
7. The operating mode selector on the operator’s panel is in Manual mode position.
When external safety devices are used check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4
(screw terminals on the panel unit) are strapped:
External limit switches
External emergency stop
XS3
A5-A6, B5-B6
A3-A4, B3-B4
Panel unit
X1.3-4, X2.3-4
X1.9-10, X2.9-10
External emergency stop, internal 24 V A1-A2, B1-B2
General stop + A11-A12, B11-B12
X1.7-8, X2.7-8
X3.10-12, X4.10-12
General stop -
Auto stop +
Auto stop -
Motor off clamping
A13-A14, B13-B14 X3.7-8, X4.7-8
A7-A8, B7-B8
A9-A10, B9-10
X3.11-12, X4.11-12
X3.7-9, X4.7-9
A15-A16, B15-16 X1.5-6, X2.5-6
For more information, see Chapter 3.9, Connection of safety chains and Chapter 3.10,
External customer connections.
Product Manual IRB 2400 31
On-Site Installation Installation and Commissioning
N.B. The air hose is sensitive to wear because it is part of the moving cable harness.
The risk of failure is greater in this case compared with a hose that is stationary and clamped.
2.16 Start-up
2.16.1 General
1. Switch on the mains switch on the cabinet.
2. The robot performs its self-test on both the hardware and software. This test takes approximately 1 minute.
If the robot is supplied with software already installed, proceed to pos. 3 below. Otherwise continue as follows (no software installed):
- Connect the batteries for memory backup (see Figure 24).
- Install the software as described in Chapter 4, Installing the Control Program.
Batteries
Connect the batteries to the connectors X3 and X4, situated below the batteries.
32
Figure 24 Location of batteries, view from above.
3. A welcome message is shown on the teach pendant display.
4. To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach pendant.
5. Update the revolution counters according to 2.16.2.
6. Check the calibration position according to section 2.16.3.
7. When the controller with the manipulator electrically connected are powered up for the first time, ensure that the power supply is connected for at least 36 hours continuously, in order to fully charge the batteries for the serial measurement board.
After having checked the above, verify that
8. the start, stop and mode selection (including the key lock switches) control devices function as intended.
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
9. each axis moves and is restricted as intended.
10. emergency stop and safety stop (where included) circuits and devices are functional.
11. it is possible to disconnect and isolate the external power sources.
12.the teach and playback facilities function correctly.
13.the safeguarding is in place.
14.in reduced speed, the robot operates properly and has the capability to handle the product or workpiece, and
15.in automatic (normal) operation, the robot operates properly and has the capability to perform the intended task at the rated speed and load.
16.The robot is now ready for operation.
2.16.2 Updating the revolution counter
When pressing the enabling device on a new robot, a message will be displayed on the teach pendant telling you that the revolution counters are not updated. When such a message appears, the revolution counter of the manipulator must be updated using the cali-
bration marks on the manipulator (see Figure 29).
Examples of when the revolution counter must be updated:
- when one of the manipulator axes has been manually moved with the controller disconnected.
- when the battery (on the manipulator) is discharged.
(it takes 36 hours with the mains switch on to recharge the battery)
- when there has been a resolver error
- when the signal between the resolver and the measuring panel unit has been interrupted
WARNING:
Working inside the robot working range is dangerous.
Press the enabling device on the teach pendant and, using the joystick, manually move
the robot so that the calibration marks lie within the tolerance zone (see Figure 29).
When all axes have been positioned as above, the revolution counter settings are stored using the teach pendant, as follows:
Product Manual IRB 2400 33
On-Site Installation Installation and Commissioning
1. Press the Misc. window key (see Figure 25).
P1
1
2
P2
P3
7 8 9
4 5 6
1 2
0
3
Figure 25 The Misc. window key from which the Service window can be chosen.
2. Select Service in the dialog box shown on the display.
3. Press Enter .
4. Then, choose View: Calibration. The window in Figure 26 appears.
File Edit
Service Calibration
View
Unit
IRB
Calib
Status
1(1)
Not rev. counter update
Figure 26 This window shows the status of the revolution counters.
If there are several units connected to the robot, these will be listed in the window.
34 Product Manual IRB 2400
Installation and Commissioning On-Site Installation
5. Select the desired unit in the window, as in Figure 26. Choose Calib: Rev. Counter
Update. The window in Figure 27 appears.
Rev. Counter Update!
IRB
To calibrate, include axes and press OK.
X
X
X
X
Axis
4
5
6
1
2
3
Status
Not updated Rev. Counter
Not updated Rev. Counter
Calibrated
Calibrated
Not updated Rev. Counter
Not updated Rev. Counter
1(6)
Incl All Cancel OK
Figure 27 The dialog box used to select axes whose revolution counters are to be updated.
6. Press the function key All to select all axes if all axes are to be updated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).
7. Confirm by pressing OK. A window like the one in Figure 28 appears.
Rev. Counter Update!
IRB
The Rev. Counter for all marked axes will be update.
It cannot be undone.
OK to continue?
Cancel OK
Figure 28 The dialog box used to start updating the revolution counter.
8. Start the update by pressing OK.
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone.
9. Check the calibration as described in Chapter 2.16.3, Checking the calibration position.
10.Save systemparameters on a floppy disk.
Product Manual IRB 2400 35
On-Site Installation
IRB 2400/ 10/ 16
Installation and Commissioning
Punch, axis 4,
3HAB 8223-1
Punch, axis 6,
3HAB 8184-1
Punch, axis 1,
3HAB 8223-1
Punch, axis 2,
3HAB 8223-1
2 markings
Punch, axis 3,
3HAB 8223-1
IRB 2400L
Punch, axis 1,
3HAB 8223-1
Punch, axis 1,
3HAB 8223-1
Punch, axis 1,
3HAB 8184-1
36
Punch, axis 1,
3HAB 8223-1
Figure 29 Calibration marks on the manipulator.
Punch, axis 1,
3HAB 8223-1
2 markings
Product Manual IRB 2400
Installation and Commissioning On-Site Installation
2.16.3 Checking the calibration position
There are two ways to check the calibration position and they are described below.
Using the diskette, Controller Parameters:
Run the program \ SERVICE \ CALIBRAT \ CAL 2400 on the diskette, follow intructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check that the cal-
revolution counters must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window and choose running axis-by-axis. Using the joystick, move the robot so that the read-out of the positions is equal to zero. Check that the calibration marks for
must be repeated.
2.16.4 Alternative calibration positions
See chapter 12, Repairs.
2.16.5 Operating the robot
Starting and operating the robot is described in the User’s Guide. Before start-up, make sure that the robot cannot collide with any other objects in the working space.
Product Manual IRB 2400 37
On-Site Installation Installation and Commissioning
38 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3 Connecting Signals
3.1 Signal classes
Power – supplies external motors and brakes.
Control signals – digital operating and data signals (digital I/O, safety stops, etc.).
Measuring signals – analog measuring and control signals (resolver and analog I/O).
Data communication signals – field bus connection, computer link.
Different rules apply to the different classes when selecting and laying cable. Signals from different classes must not be mixed.
3.2 Selecting cables
All cables laid in the controller must be capable of withstanding 70 o
C. In addition, the following rules apply to the cables of certain signal classes:
Power signals -Shielded cable with an area of at least 0.75 mm
2
or AWG 18. Note that any local standards and regulations concerning insulation and area must always be complied with.
Control signals – Shielded cable.
Measuring signals – Shielded cable with twisted pair conductors.
Data communication signals – Shielded cable with twisted pair conductors. A specific cable should be used for field 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 screened and has four conductors, two for electronic supply and two for signal transmission.
Note that a separate cable for supply of I/O load 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.
Product Manual IRB 2400 39
Connecting Signals Installation and Commissioning
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.
3.3 Interference elimination
Internal relay coils and other units that can generate interference inside the controller are neutralised. External relay coils, solenoids, and other units must be clamped in a
similar way. Figure 30 illustrates how this can be done.
Note that the turn-off time for DC relays increases after neutralisation, especially if a diode is connected across the coil. Varistors give shorter turn-off times. Neutralising the coils lengthens the life of the switches that control them.
+24 V DC +0 V
The diode should be dimensioned for the same current as the relay coil, and a voltage of twice the supply voltage.
The varistor should be dimensioned for the same energy as the relay coil, and a voltage of twice the supply voltage.
+24 V DC, or AC voltage
R C
+0 V
R 100 ohm, 1W
C 0.1 - 1
µ
F
> 500 V max voltage
125 V nominal voltage
Figure 30 Examples of clamping circuits to suppress voltage transients.
3.4 Connection types
I/O, external emergency stops, safety stops, etc., can be supplied on screwed connections or as industrial connectors.
Designation
X(T) Screwed terminal
XP
XS
Male (pin)
Sockets (female)
40 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.5 Connections
Detailed information about connection locations and functions will be found in chapter
11, Circuit Diagram.
3.5.1 To screw terminal
Panel unit and I/O units are provided with keyed screw terminals for cables with an area between 0.25 and 1.5 mm
2
. A maximum of two cables may be used in any one connection. The cable screen must be connected to the cabinet wall using EMC. It should be noted that the screen must continue right up to the screw terminal.
The installation should comply with the IP54 (NEMA 12) protective standard.
Bend unused conductors backwards and attach them to the cable using a clasp, for example. In order to prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends.
3.5.2 To connectors (option)
Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652) can be found on the left-hand side or front of the cabinet (depending on the customer
order) See Figure 31 and Figure 22.
In each industrial connector there is space 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.
The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included).
Bend unused conductors backwards and attach them to the cable using a clasp, for example. In order to prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends.
When contact crimping industrial connectors, the following applies:
Using special tongs, press a pin or socket on to each non-insulated conductor.
The pin can then be snapped into the actual contact.
Push the pin into the connector until it locks.
Also, see instructions from contact supplier.
A special extractor tool must be used to remove pins from industrial connectors.
When two conductors must be connected to the same pin, both of them are pressed into the same pin. A maximum of two conductors may be pressed into any one pin.
Product Manual IRB 2400 41
Connecting Signals
Space for cable glands
Prepared for further connectors
XS17,
CAN bus connector
Installation and Commissioning
XS 3 (safety)
XS 5 (customer signals)
XS 6 (customer power)
XS 7 (external axes)
XS 8, Position switch
XS 1, Motor cable
XS 2, Measurement system cable
Figure 31 Positions for connections on the left-hand side of the controller.
42 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.6
Customer connections on manipulator
For connection of extra equipment on the manipulator, there are cables and air hose integrated into the manipulator’s cabling, one Burndy UTG 014 12SHT-connector and one Burndy UTG 018 23SHT-connector on the rear part of the upper arm.
Connections: R1/4” in the rear part of the upper arm and at the base. Max. 8 bar.
Inner hose diameter: 8 mm.
N.B The air hose is sensitive to wear because it is part of the moving cable harness.
The risk of failure is greater in this case compared with a hose that is stationary and clamped.
When option 04y is chosen, the customer connections are available at the front of the upper arm.
Number of signals:
IRB 2400/10 and /16
IRB 2400L
23 (50 V, 250 mA), 10 (250 V, 2 A), one protective earth.
12 (60 V, 500 mA)
R1.CP/CS
Air R1/4”
R3.CP
R3.CS
Air R1/4”
R2.CP
R2.CS
Air R1/4”
Figure 32 Location of customer connections, IRB 2400/10, /16.
R1.CS
Air R 1/4”
R2.CS
Air R 1/4”
Figure 33 Location of customer connections, IRB 2400L.
Product Manual IRB 2400 43
Connecting Signals Installation and Commissioning
To connect to power and signal conductors from the connection unit to the manipulator base and on the upper arm, the following parts are recommended:
IRB 2400/10, /16
4
5
6
1
2
3
Connector R1.CP/CS Signals on the manipulator base. (Regarding Item No see
Item
No.
Name ABB part no.
Type Comments
Female insert 40p
Hood
3HAB 7284-1
3HAB 7285-1
DIN 43 652
DIN 43 652
Compression gland 3HAB 7283-1 DS/55 ZU, DN
155D, E155
PFLITSCH
Socket
Sockets
Key pin
5217 1021-4
5217 1021-5
5217 687-9
DIN 43 652
DIN 43 652
DIN 43 652
0.14-0.5 mm
2
0.5-1.5 mm
2
44
IRB 2400/10, /16
5
6
7
8
1
2
Connector R2.CS/R3.CS Signals on the upper arm. (Regarding Item No. see Figure 35)
Item
No.
Name ABB part no.
Type Comments
Socket con. 23p
Gasket
3HAA 2613-3 UTO
01
8 23 SHT Burndy
2152 0363-5 UTFD 16 B Burndy
3 Socket See Pin and
See socket table below
4 Burndy EMC
Burndy
Pin connector 23p 3HAA 2602-3
5217 649-34
Pin See Pin and
Socket table below
Adaptor
UTO 618 23 PN04
UTO 618 23 PN
3HAA 2601-3
5217 1038-5
UTG 18 ADT
UTG 18 AD
5217 649-36 UTG 18 PG Cable clamp
Shrinking hose
Shrinking hose
3HAA 2614-3
5217 1032-5
Burndy EMC
Burndy
Burndy
Bottled shaped
Angled
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
IRB 2400/10, /16
7
8
1
2
Connector R2.CP./R3.CP. Power on the upper arm.
(Regarding Item No. see Figure 35)
Item
No.
Name ABB part no.
Type
Socket con. 12p
Gasket
Comments
3HAA 2613-2 UTO
01
4 12 SHT Burndy
5217 649-64 UTFD 13 B Burndy
3
4
5
Socket See socket table below
Pin connector 12p 3HAA 2602-2
5217 649-7
Pin See pin table below
UTO 614 12 PN04
UTO 614 12 PN
Burndy EMC
Burndy
6 Adaptor UTG 14 ADT
UTG 14 AD
UTG 14 PG Cable clamp
Shrinking hose
Shrinking hose
3HAA 2601-2
5217 1038-3
5217 649-8
3HAA 2614-2
5217 1032-4
Burndy EMC
Burndy
Burndy
Bottled shaped
Angled
IRB 2400L
7
8
5
6
3
4
1
2
Connector R2.CS. Signals, on upper arm. (Regarding Pos see Figure 35)
Pos Name ABB art. no.
Type Comments
Socket connector
Gasket
3HAA 2613-2
5217 649-64
UTO 014 12 SHT
UTFD 13B
Burndy
Burndy
Socket
Pin connector 12p
Pin
Adaptor
Cable clamp
Shrinking hose
Shrinking hose
See below
3HAA 2602-2
5217 649-7
See below
3HAA 2601-2
5217 1038-3
5217 649-8
3HAA 2614-2
5217 1032-4
UTO 61412PN04
UTO 61412PN
URG 14 ADT
UTG 14 AD
UTG 14 PG
Burndy EMC
Burndy
Burndy EMC
Burndy
Burndy
Bottled shaped
Angled
Product Manual IRB 2400 45
Connecting Signals
IRB 2400L
Installation and Commissioning
7
8
5
6
3
4
1
2
Connector R1CS. Signals, on the manipulator base. (Regarding Pos see Figure 35)
Pos Name ABB art. no.
Type Comments
Pin connector 12p
Gasket
3HAA 2599-2
5217 649-64
UTG 014 12 P
UTFD 14 B
Burndy
Burndy
Pin
Socket con. 12p
Sockets
Adaptor
Cable clamp
Shrinking hose
Shrinking hose
See below
3HAA 2600-2
See below
3HAA 2601-2
5217 1038-3
5217 649-8
3HAA 2614-2
5217 1032-4
UTO 61412 S
URG 14 ADT
UTG 14 AD
UTG 14 PG
Burndy EMC
Burndy EMC
Burndy
Burndy
Bottled shaped
Angled
Name
Pin
Socket
ABB part no.
Type
5217 649-72
5217 649-25
5217 649-70
5217 649-3
5217 649-68
5217 649-10
5217 649-31
5217 649-73
5217 649-26
5217 649-71
5217 649-69
5217 1021-4
24/26
24/26
20/22
20/22
16/20
24/26
16/20
24/26
24/26
20/22
16/18
DIN 43 652
5217 1021-5 DIN 43 652
Comments
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Ground
Burndy Ground
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Machine tooling
Tin bronze (CuSu)
0.14 - 0.5mm
2
AWG 20-26
Tin bronze (CuSu)
0.5 - 1.5mm
2
AWG 16-20
46 Product Manual IRB 2400
Installation and Commissioning
3
Connecting Signals
2
6
1
Figure 34 Customer connector
Customer side
4 5
4, 5
Manipulator side
1, 3
8
6
2
Figure 35 Burndy connector
7
Product Manual IRB 2400 47
Connecting Signals Installation and Commissioning
3.7 Connection to screw terminal
Sockets with screwed connections for customer I/O, external safety circuits, customer sockets on the robot, external supply to electronics.
Signal identification Location
Safeguarded stop
Digital I/O
Combi I/O
Relay I/O
RIO I/O
SIO 1, SIO 2
CAN1 (internal unit)
Panel unit
I/O unit
I/O unit
I/O unit
I/O unit
Backplane
Panel unit
CAN 2 (manipulator, I/O units) Backplane
CAN 3 (external I/O units) Backplane
24 V supply (2 A fuse)
115/230 V AC supply
Terminals
X1 - X4
X1 - X4
X1 - X4, X6
X1 - X4
X1, X2
X1, X2
X9
X16
X10
XT31
XT21
Location of socket terminals are shown below. See also circuit diagram, “View of control cabinet”, for more details.
I/O units (x4)
X1 (SIO1)
X2 (SIO2)
X10 (CAN3)
X16 (CAN2)
Backplane alt. D-sub
X1 - 4
Panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN MS NS
ES1 ES2 GS1 GS2 AS1 AS2
X5 X8
X6 CONTROL PANEL
48
XT5, customer signals
XT6, customer power
XT8, position switch
XT21 (115/230 V ACsupply)
XT31 (24V supply)
Figure 36 Screw terminal locations.
X9 (CAN1))
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.8 The MOTORS ON / MOTORS OFF circuit
To set the robot to MOTORS ON mode, two identical chains of switches must be closed. If any switch is open, the robot will switch to MOTORS OFF mode. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
Figure 37 shows an outline principal diagram of the available customer connections, AS, GS and
ES.
LS
Solid state switches
Contactor
ES
&
2nd chain interlock
Drive unit
GS
TPU En
AS
Auto
Operating mode selector
Manual
EN RUN
Computer commands
M
LS
AS
= Limit switch
= Automatic mode safeguarded space Stop
TPU En= Enabling device, teach pendant unit
GS = General mode safeguarded space Stop
ES = Emergency Stop
Figure 37 MOTORS ON /MOTORS OFF circuit.
Product Manual IRB 2400 49
Connecting Signals Installation and Commissioning
3.9 Connection of safety chains
24 V *
X3:12
X4:12
24 V
Ext LIM1
X1:4 3
X3:10
8
11
9
ES1
+ Opto isol.
-
GS1
TPU En1
+
Opto isol.
-
AS1
Auto1 Man1
&
EN
RUN
0 V
24 V
External contactors
X2:5 6 CONT1
X1:5 6 CONT2
0 V
Ext LIM2
X2:4 3
ES2
X4:10
8
+
Opto isol.
-
GS2
TPU En2
11
+
Opto isol.
AS2
9 -
Auto2
Man2
X3:7 *
X4:7
0 V
*)
Supply from internal 24V (X3/X4:12) and 0 V (X3/
X4:7) is displayed.
When external supply of GS and AS, X3/X4:10,11 is connected to 24 V and X3/X4:8,9 is connected to external 0 V
&
X1-X4 connection tables, see section 3.10.
Interlocking
K1
K2
K1
K2
24V
Drive unit
M
0 V
Technical data per chain
Limit switch: load max. V drop
300 mA
1 V
External contactors: load max. V drop
GS/AS load at 24V
GS/AS closed “1”
GS/AS open “0”
External supply of GS/AS
Max. potential relative to the cabinet earthing and other group of signals
Signal class
10 mA
4 V
25 mA
> 18 V
< 5 V max. +35VDC min. -35VDC
300 V control signals
Figure 38 Diagram showing the two-channel safety chain.
50 Product Manual IRB 2400
Installation and Commissioning
3.9.1 Connection of ES1/ES2 on panel unit
External
24V 0V
Internal
24V 0V
External
X1:10 X1:9
X1:7
X1:8
Connecting Signals
TPU
E-stop relay
Cabinet
Supply from internal 24V
(X1/X2:10) and 0V (X1/
X2:7) is displayed. When external supply, X1/X2:9 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).
External
0V 24V
Internal
0V 24V
External
X2:10
X2:9
X1:2
ES1 out
X1:1
TPU
X2:7 X2:8
E-stop relay
Cabinet
Chain 1
Chain 2
Technical data
ES1 and 2 out max. voltage 120 VAC or 48 VDC
ES1 and 2 out max. current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relays = min 22 V between terminals X1:9,8 and
X2:9,8 respectively
Rated current per chain 40 mA
Max. potential relative to the cabinet earthing and other groups of signals
Signal class
300 V control signals
Figure 39 Terminals for emergency circuits.
X2:2
ES2 out
X2:1
Product Manual IRB 2400 51
Connecting Signals Installation and Commissioning
3.9.2 Connection to Motor On/Off contactors
K1 (Motor On/Off 1)
K2 (Motor On/Off 2)
X3:2
1
X4:2
1
Figure 40 Terminals for customer use.
Technical data
Max. voltage 48V DC
Max. current
Max. potential relative to the cabinet earthing and other groups of signals
Signal class
4A
300V control
52
3.9.3 Connection to operating mode selector
X3:3
Auto1
MAN1
100%
4
5
6
X4:3
Auto2
MAN2 100%
4
5
6
Figure 41 Terminals customer use.
3.9.4 Connection to brake contactor
Technical data
Max. voltage 48V DC
Max. current
Max. potential relative to the cabinet earthing and other groups of signals
Signal class
4A
300V control
K3 (Brake)
X1:12
11
Technical data
Max. voltage 48V DC
Max. current
Max. potential relative to the cabinet earthing and other groups of signals
Signal class
4A
300V control
Figure 42 Terminal for customer use.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.10 External customer connections
Customer contacts, on panel unit: X1- X4.
WARNING!
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN MS NS ES1 ES2 GS1 GS2 AS1 AS2
X1
1 2 3 4 5 6 7 8 9 10 11 12
X2
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
X3
1 2 3 4 5 6 7 8 9 10 11 12
X4
Chain status
LED´s
= jumper
Customer connections: X1 - X4, located on the panel unit.
The signal names refer to the circuit diagram in chapter 11.
Signal name
ES1 out:B
ES1 out:A
Ext. LIM1:B
Ext. LIM1:A
0V
CONT1
Int. 0V ES1
Ext. 0V ES1
Ext. ES1 IN 9
Ext. ES1 OUT 10
Ext. BRAKE B 11
Ext. BRAKE A 12
6
7
8
3
4
5
X1
Pin
1
2
Comment
Emergency stop out chain 1
Emergency stop out chain 1
External limit switch chain 1
External limit switch chain 1
0V external contactor 1
External contactor 1
Internal supply 0V of emergency stop chain 1
External supply 0V of emergency stop chain 1
External emergency stop in chain 1
External emergency stop out chain 1
Contactor for external brake
Contactor for external brake
Product Manual IRB 2400 53
Connecting Signals
54
Installation and Commissioning
Signal name
ES2 out:B
ES2 out:A
Ext. LIM2:B
Ext. LIM2:A
24V panel
CONT2
Int. 24V ES2
Ext. 24V ES2
Ext. ES2 IN
Ext. ES2 OUT 10
11
12
X2
Pin
1
2
Comment
Emergency stop out chain 2
3
4
Emergency stop out chain 2
External limit switch chain 2
5
6
External limit switch chain 2
24V external contactor 2
External contactor 2
7 Internal supply 24V of emergency stop chain 2
8 External supply 24V of emergency stop chain 2
9 External emergency stop in chain 2
External emergency stop out chain 2
Not used
Not used
Signal name
Ext. MON 1:B
X3
Pin
1
Ext. MON 1:A 2
Ext. com 1
Ext. auto 1
3
4
Ext. man 1
Ext. man FS 1
0V
GS1-
7
8
5
6
AS1-
GS1+
AS1+
24V panel
9
10
11
12
Comment
Motor contactor 1
Motor contactor 1
Common 1
Auto 1
Manual 1
Manual full speed 1
0V to auto stop and general stop
General stop minus chain 1
Auto stop minus chain 1
General stop plus chain 1
Auto stop plus chain 1
24V to auto stop and general stop
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Signal name
X4
Pin
Ext. MON 2:B 1
Ext. MON 2:A 2
Ext. com 2 3
Ext. auto 2
Ext. man 2
Ext. man FS 2
0V
6
7
4
5
GS2-
AS2-
GS2+
AS2+
24V panel
10
11
8
9
12
Comment
Motor contactor 2
Motor contactor 2
Common 2
Auto 2
Manual 2
Manual full speed 2
0V to auto stop and general stop
General stop minus chain 2
Auto stop minus chain 2
General stop plus chain 2
Auto stop plus chain 2
24V to auto stop and general stop
Product Manual IRB 2400 55
Connecting Signals Installation and Commissioning
3.11 External safety relay
The Motor On/Off mode in the controller can operate with external equipment if external relays are used. Two examples are shown below.
Panel unit Relays with positive action
K2
K1
Ext MON 2
CONT2
24 V
X2:6
X2:5
X4:2
X4:1
X3:2
Ext MON 1
0 V
CONT1
X3:1
X1:5
X1:6
0 V
24 V
56
Robot 1
External supply
External supply
Cell ES
ES out
AS GS
Safety gate
Robot 2
ES out
AS GS
(only one channel displayed)
To other equipment
Safety relay
Figure 43 Diagram for using external safety relays.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.12 Safeguarded space stop signals
According to the safety standard ISO/DIS 11161 “Industrial automation systems - safety of integrated manufacturing systems - Basic requirements”, there are two categories of safety stops, category 0 and category 1, see below:
The category 0 stop is to be used when, for safety analysis purposes, the power supply to the motors must be switched off immediately, such as when a light curtain, used to protect against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop.
Category 1 is to be preferred, if accepted for safety analysis purposes, such as when gates are used to protect against entry into the work cell. This controlled motion stop takes place within the programmed path, which makes restarting easier.
3.12.1 Delayed safeguarded space stop
All the robot’s safety stops are as default category 0 stops.
Safety stops of category 1 can be obtained by activating the delayed safeguarded space stop together with AS or GS. A delayed stop gives a smooth stop. The robot stops in the same way as a normal program stop with no deviation from the programmed path. After approx. 1 second the power supply to the motors is shut off. The function is activated by setting a parameter, see User’s Guide, section System Parameters, Topic: Controller.
Note! To ensure MOTORS OFF status, the activating switch must be kept open for more than one second. If the switch is closed within the delay, the robot stops and will remain in MOTORS ON mode.
3.13 Available voltage
3.13.1 24 V I/O supply
The robot has a 24 V supply available for external and internal use.
This voltage is used in the robot for supplying the drive unit fans and the manipulator brakes.
The 24 V I/O is not galvanically separated from the rest of the controller voltages.
Technical data
Voltage
Ripple
Permitted customer load
Current limit
Short-circuit current
24.0 - 26.4 V
Max. 0.2 V
Max. 6 A (7.5 A if DSQC 374)
Max. 18 A (12 A if DSQC 374)
Max. 13 A (average value)(~ 0 A if DSQC 374)
Product Manual IRB 2400 57
Connecting Signals Installation and Commissioning
24 V I/O available for customer connections at:
XT.31.2
XT.31.1
XT.31.4
24 V (via 2 A fuse) for own fuses, max. fuse size is 2 A to ensure breaking at short circuit
Note! DSQC 374 can not trip any fuses.
0 V (connected to cabinet structure)
3.13.2 115/230 V AC supply
The robot has a AC supply available for external and internal use.
This voltage is used in the robot for supplying optional service outlets.
The AC supply is not galvanically separated from the rest of the controller voltages.
Technical data
Voltage
Permitted customer load
Fuse size
115 or 230 V
Max. 500 VA
3.15 A (230 V), 6.3 A (115 V)
AC supply is available for customer connections at:
XT.21.1-5 230 V (3.15 A)
XT.21.6-8 115 V (6.3 A)
XT.21.9-13 N (connected to cabinet structure)
3.14 External 24 V supply
An external supply must be used in the following cases:
58
• When the internal supply is insufficient
• When the emergency stop circuits must be independent of whether or not the robot has power on, for example.
• When there is a risk that major interference can be carried over into the internal
24 V supply
An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I/O units or on the panel unit.
The neutral wire in the external supply must be connected in such a way as to prevent the maximum permitted potential difference in the chassis earth being exceeded. For example, a neutral wire can be connected to the chassis earth of the controller, or some other common earthing point.
Technical data:
Potential difference to chassis earth:
Permitted supply voltage:
Max. 60 V continuous
Max. 500 V for 1 minute
I/O units 19 - 35 V including ripple panel unit 20.6 - 30 V including ripple
Product Manual IRB 2400
Installation and Commissioning
3.15 Connection of extra equipment to the manipulator
Technical data for customer connections
Power supply
Conductor resistance <0,5 ohm, 0,241 mm
2
Max. voltage
Max. current
250 V AC
2 A
Signals
Conductor resistance <3 ohm, 0.154 mm
2
Max. voltage
Max. current
50 V AC / DC
250 mA
3.15.1 Connections on upper arm, IRB 2400/10, /16
Connecting Signals
Air R1/4”
R2.CS
R2.CP
Figure 44 Customer connections on upper arm.
Signal name Customer terminal controller,
(optional)
Power supply
CPA
CPB
CPC
CPD
CPE
CPF
XT6.1
XT6.2
XT6.3
XT6.4
XT6.5
XT6.6
CPJ
CPK
CPL
CPM
XT6.H
XT6.7
XT6.8
XT6.9
XT6.10
Customer contact on upper arm, R2
R2.CP.A
R2.CP.B
R2.CP.C
R2.CP.D
R2.CP.E
R2.CP.F
R2.CP.G
Ground
R2.CP.H
Key pin
R2.CP.J
R2.CP.K
R2.CP.L
R2.CP.M
Customer contact on manipulator base
(cable not supplied)
RI.CP/CS.A1
RI.CP/CS.B1
RI.CP/CS.C1
RI.CP/CS.D1
RI.CP/CS.A2
RI.CP/CS.B2
RI.CP/CSP Ground
RI.CP/CS.C2
RI.CP/CS.D2
RI.CP/CS.A3
RI.CP/CS.B3
Product Manual IRB 2400 59
Connecting Signals
CSH
CSJ
CSK
CSL
CSM
CSN
CSP
CSR
Signals
CSA
CSB
CSC
CSD
CSE
CSF
CSG
CSS
CST
CSU
CSV
CSW
CSX
CSY
CSZ
XT5.1
XT5.2
XT5.3
XT5.4
XT5.5
XT5.6
XT5.7
XT5.8
XT5.9
XT5.10
XT5.11
XT5.12
XT5.13
XT5.14
XT5.15
XT5.16
XT5.17
XT5.18
XT5.19
XT5.20
XT5.21
XT5.221
XT5.23
Installation and Commissioning
R2.CS.A
R2.CS.B
R2.CS.C
R2.CS.D
R2.CS.E
R2.CS.F
R2.CS.G
R2.CS.H
R2.CS.J
R2.CS.K
R2.CS.L
R2.CS.M
R2.CS.N
R2.CS.P
R2.CS.R
R2.CS.S
R2.CS.T
R2.CS.U
R2.CS.V
R2.CS.W
R2.CS.X
R2.CS.Y
R2.CS.Z
3.15.2 Connections on upper arm, IRB 2400L
R1.CS/CP.B5
R1.CS/CP.C5
R1.CS/CP.D5
R1.CS/CP.A6
R1.CS/CP.B6
R1.CS/CP.C6
R1.CS/CP.D6
R1.CS/CP.A7
R1.CS/CP.B7
R1.CS/CP.C7
R1.CS/CP.D7
R1.CS/CP.A8
R1.CS/CP.B8
R1.CS/CP.C8
R1.CS/CP.D8
R1.CS/CP.A9
R1.CS/CP.B9
R1.CS/CP.C9
R1.CS/CP.D9
R1.CS/CP.A10
R1.CS/CP.B10
R1.CS/CP.C10
R1.CS/CP.D10
R2.CS
Figure 45 Customer connections on upper arm.
60
Signal name Customer terminal controller,
(optional)
Signals
CSA
CSB
XT5.1
XT5.2
Customer contact on upper arm, R2
R2.CS.A
R2.CS.B
Customer contact on manipulator base
(cable not supplied)
R1.CS.A
R1.CS.B
Product Manual IRB 2400
Installation and Commissioning
CSC
CSD
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
XT5.3
XT5.4
XT5.5
XT5.6
XT5.7
XT5.8
XT5.9
XT5.10
XT5.11
XT5.12
R2.CS.C
R2.CS.D
R2.CS.E
R2.CS.F
R2.CS.G
R2.CS.H
R2.CS.J
R2.CS.K
R2.CS.L
R2.CS.M
3.15.3 Connection of signal lamp on upper arm (option)
Connecting Signals
R1.CS.C
R1.CS.D
R1.CS.E
R1.CS.F
R1.CS.G
R1.CS.H
R1.CS.J
R1.CS.K
R1.CS.L
R1.CS.M
Signal lamp
IRB 2400/10, /16
R3.H1 +
R3.H2 -
Signal lamp
IRB 2400L
Figure 46 Location of signal lamp.
3.16 Distributed I/O units
3.16.1 General
Up to 20* units can be connected to the same controller but only four of these can be installed inside the controller. Normally a distributed I/O unit is placed outside the controller. The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to the other end). The controller can be one of the end points or be placed somewhere in the middle of the chain. For setup parameters, see User’s Guide, section System Parameters, Topic: I/O Signals.
*) some ProcessWare reduces the number due to use of SIM boards.
Product Manual IRB 2400 61
Connecting Signals Installation and Commissioning
3.16.2 Sensors
Sensors are connected to one optional digital unit.
Technical data
See Product Specification IRB 2400, chapter 3.10.
The following sensors can be connected:
Sensor type
Digital one bit sensors
Digital two bit sensors
Signal level
High
Low
High
No signal
Low
Error status
“1”
“0”
“01”
“00”
“10”
“11” (stop program running)
62
3.16.3 Connection and address keying of the CAN-bus
Controller
Panel unit:
X9 CAN1
Back plane:
X10 CAN3
X16 CAN2
I/O unit I/O unit
I/O unit
X9/X10/X16. 1 0V_CAN
2 CAN_L
3 drain
4 CAN_H
5 24V_CAN
X5. 1
2
3
4
5
0V_CAN
CAN_L drain
CAN_H
24V_CAN
X5. 1
2
3
4
5
Termination of last unit
120
Ω
Figure 47 Example of connection of the CAN-bus
1. When the I/O unit is fitted inside the control cabinet (this is standard when choosing the options on the Specification form), its CAN bus is connected to CAN1, X9 on the panel
unit (see 3.7). No termination is required when only CAN1 is used.
2. When the I/O unit is fitted outside the control cabinet, its CAN bus must be connected to
CAN3, X10 on the backplane of the control cabinet.
3. When the I/O unit is fitted on the manipulator, its CAN bus must be connected to CAN2,
X16 on the backplane of the control cabinet.
NOTE!
When only one of the X10/X16 is connected, the other must be terminated with 120
Ω
.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
24V_CAN must not be used to supply digital inputs and outputs. Instead, they must be supplied either by the 24 V I/O from the cabinet or externally by a power supply unit.
6
CAN3 (ext. I/O)
CAN2 (manip. I/O)
6
1
1
Figure 48 CAN connections on back plane.
DeviceNet Connector
Input and ID
12
1
X5
Signal name Pin Description
V- 0V
CAN_L
1
2
Supply voltage GND
CAN signal low
DRAIN
CAN_H
V+
GND
3
4
5
6
Shield
CAN signal high
Supply voltage 24VDC
Logic GND
MAC ID 0
MAC ID 1
MAC ID 2
MAC ID 3
MAC ID 4
MAC ID 5
7
8
9
10
11
12
Board ID bit 0 (LSB)
Board ID bit 1
Board ID bit 2
Board ID bit 3
Board ID bit 4
Board ID bit 5 (MSB)
Product Manual IRB 2400 63
Connecting Signals Installation and Commissioning
ID setting
Each I/O unit is given a unique address (ID). The connector contains address pins and can
be keyed as shown in Figure 49.
When all terminals are unconnected the highest address is obtained, i.e. 63. When all are connected to 0 V, the address is 0 (which will cause an error since address 0 is used by the
Panel unit). To not interfer with other internal addresses, do not use address 0-9.
1 2 3 4 5
(0V)
6 7 8 9 10 11 12
X5 contact address pins address key
64
Example:
To obtain address 10: cut off address pins 2 and 8, see figure.
To obtain address 25: cut off address pins 1, 8 and 16.
1 4
2 8
16
32
Figure 49 Examples of address keying.
3.16.4 Digital I/O DSQC 328 (optional)
The digital I/O unit has 16 inputs and outputs, divided up into groups of eight. All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply.
Technical data
See Product Specification IRB 2400, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
CONNECTION TABLE
Customer contacts: X1 - X4
Status LED’s
1 2 3 4 5 6 7 8
OUT
IN
X1
X3
1 10
X2
X4
1
MS
NS
9 10 11 12 13 14 15 16
10
1 10
1 10
OUT
IN
12 1
X5
Unit function Signal name
Opto.
isol.
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
7
8
0V for out 1-8 9
24V for out 1-8 10*
5
6
3
4
X1 X2
Pin Customer conn.
Signal name Pin
1
2
Out ch 9
Out ch 10
1
2
0V
24V
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
0V for out 9-16
24V for out 9-16
7
8
9
10*
5
6
3
4
*)
If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program.
Product Manual IRB 2400 65
Connecting Signals Installation and Commissioning
Unit function Signal name
Opto.
isol.
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0V for in 1-8
Not used
9
10
7
8
5
6
3
4
X3
Pin Customer conn.
1
2
24 V
0 V
X4
Signal name Pin
In ch 9
In ch 10
1
2
In ch 11
In ch 12
In ch 13
In ch 14
5
6
3
4
In ch 15
In ch 16
0V for in 9-16
Not used
9
10
7
8
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100
Ω) may be used.
66 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.16.5 AD Combi I/O DSQC 327 (optional)
The combi I/O unit has 16 digital inputs divided into groups of 8, and 16 digital outputs divided into two groups of 8. All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply.
The two analog outputs belong to a common group which is galvanically isolated from the electronics of the controller. The supply to the two analog outputs is generated from
24 V_CAN (with galvanically isolated DC/AC converter).
Technical data
See Product Specification IRB 2400, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Product Manual IRB 2400 67
Connecting Signals Installation and Commissioning
CONNECTION TABLE
Customer contacts: X1 - X4, X6
Status LED’s
1 2 3 4 5 6 7 8
OUT
IN
X1
X3
1 10
X2
X4
1
MS
NS
9 10 11 12 13 14 15 16
10
X6
1
OUT
IN
1 10 1 10
6
12 1
X5
Unit function Signal name
Opto.
isol.
Out ch 1
Out ch 2
Out ch 3
Out ch 4
Out ch 5
Out ch 6
Out ch 7
Out ch 8
7
8
0V for out 1-8 9
24V for out 1-8 10*
5
6
3
4
X1 X2
Pin Customer conn.
Signal name Pin
1
2
Out ch 9
Out ch 10
1
2
0V
24V
Out ch 11
Out ch 12
Out ch 13
Out ch 14
Out ch 15
Out ch 16
0V for out 9-16
24V for out 9-16
7
8
9
10*
5
6
3
4
*)
If supervision of the supply voltage is required, a bridge connection can be made to an optional digital input. The supervision instruction must be written in the RAPID program.
68 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Unit function Signal name
Opto.
isol.
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0V for in 1-8
Not used
9
10
7
8
5
6
3
4
X3
Pin Customer conn.
1
2
24 V
0 V
X4
Signal name Pin
In ch 9
In ch 10
1
2
In ch 11
In ch 12
In ch 13
In ch 14
5
6
3
4
In ch 15
In ch 16
0V for in 9-16
Not used
9
10
7
8
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100
Ω) may be used.
Signal name
AN_ICH1
AN_ICH2
0V
0VA
AN_OCH1
AN_OCH2
4
5
6
X6
Pin Explanation
1 For test purpose only
2 For test purpose only
3 0V for In 1-2
0V for Out 1-2
Out ch 1
Out ch 2
Product Manual IRB 2400 69
Connecting Signals Installation and Commissioning
3.16.6 Analog I/O DSQC 355 (optional)
The analog I/O unit provides following connections:
4 analog inputs, -10/+10V, which may be used for analog sensors etc.
4 analog outputs, 3 for -10/+10V and 1 for 4-20mA, for control of analog functions such as controlling glueing equipment etc.
24V to supply external equipment wich return signals to DSQC 355.
Technical data
See Product Specification IRB 2400, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
70 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
CONNECTION TABLE
Customer contacts: X1, X3, X 5 - X8
X8-Analog inputs X7-Analog outputs
Bus staus LED’s
X8
S2 S3
X2
X5 X3
X7
Analog I/O
DSQC 355
ABB flexible Automation
X5-DiviceNet input and ID connector
Not to be used
Figure 50 Analog I/O unit
Connector X5- DeviceNet connectors
See section 3.16.3 on page 62.
Product Manual IRB 2400 71
Connecting Signals Installation and Commissioning
12
24
Connector X7 - Analog outputs
1
13
X7
Signal name Pin Description
ANOUT_1
ANOUT_2
1
2
Analog output 1, -10/+10V
Analog output 2, -10/+10V
ANOUT_3
ANOUT_4
Not to be used 5
Not to be used 6
3 Analog output 3, -10/+10V
4 Analog output 4, 4-20 mA
Not to be used 7
Not to be used 8
Not to be used 9
Not to be used 10
Not to be used 11
Not to be used 12
Not to be used 13
Not to be used 14
Not to be used 15
Not to be used 16
Not to be used 17
Not to be used 18
GND
GND
GND
GND
GND
GND
23
24
19 Analog output 1, 0 V
20 Analog output 2, 0 V
21 Analog output 3, 0 V
22 Analog output 4, 0 V
72 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Connector X8 - Analog inputs
16
32
1
17
X8
Signal name Pin Description
ANIN_1
ANIN_2
1
2
Analog input 1, -10/+10 V
Analog input 2, -10/+10 V
ANIN_3
ANIN_4
Not to be used 5
Not to be used 6
3 Analog input 3, -10/+10 V
4 Analog input 4, -10/+10 V
Not to be used 7
Not to be used 8
Not to be used 9
Not to be used 10
Not to be used 11
Not to be used 12
Not to be used 13
Not to be used 14
Not to be used 15
Not to be used 16
+24V out
+24V out
17
18
+24VDC supply
+24VDC supply
+24V out
+24V out
+24V out
+24V out
19
20
21
22
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
+24V out
+24V out
GND
GND
GND
GND
GND
GND
GND
GND
23
24
25
26
27
28
29
30
31
32
+24VDC supply
+24VDC supply
Analog input 1, 0V
Analog input 2, 0V
Analog input 3, 0V
Analog input 4, 0V
Product Manual IRB 2400 73
Connecting Signals Installation and Commissioning
3.16.7 Encoder interface unit, DSQC 354
The encoder interface unit provides connections for 1 encoder and 1 digital input.
The encoder is used for installation on a conveyor to enable robot programs to synchronize to the motion (position) of the conveyor.
The digital input is used for external start signal/ conveyor synchronization point.
Further information
User Reference Description Conveyor Tracking.
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Customer terminals:
X20
Conveyor connection
X20
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
CAN Rx
CAN Tx
MS
NS
POWER
X5 X3
X5-DeviceNet input and ID connector
X3
Not to be used
Device Net connector X5, see section 3.16.3 on page 62
Figure 51 Encoder unit, DSQC 354
74 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
24 V I/O or external supply
0 V
Encoder
Synch switch
A
B
24 V DC
0 V
24 V DC
0 V
10-16 not to be used
8
9
6
7
10
3
4
1
2
5
11
12
13
14
15
16
Encoder unit
Opto
Opto
Opto
Opto
Opto
Opto
Galvanic insulation
Figure 52 Encoder connections.
The wiring diagram in Figure 52 shows how to connect the encoder and start signal
switch to the encoder unit. As can be seen from the illustration, the encoder is supplied with 24 VDC and 0V. The encoder output 2 channels, and the on-board computer uses quadrature decoding (QDEC) to compute position and direction.
Product Manual IRB 2400 75
Connecting Signals Installation and Commissioning
Connector X20 - Encoder and digital input connections
Input and ID
1
16
X20
Signal name Pin Description
24 VDC
0 V
1
2
24 VDC supply
0 V
ENC
ENC
ENC_A
ENC_B
3
4
5
6
Encoder 24 VDC
Encoder 0 V
Encoder Phase A
Encoder Phase B
DIGIN
DIGIN
7 Synch switch 24 VDC
8 0V
DIGIN 9 Synch switch digital input
Not to be used 10
Not to be used 11
Not to be used 12
Not to be used 13
Not to be used 14
Not to be used 15
Not to be used 16
76 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Status
LED’s
3.16.8 Relay I/O DSQC 332
16 output relays each with a single Normal Open contact, independent of each other.
16 digital 24V inputs divided into groups of 8. The groups are galvanically isolated.
Supply to customer switches can be taken either from the cabinet 24 V I/O or from a separate supply.
Technical data
See Product Specification IRB 2400, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
CONNECTION TABLE
Customer contacts: X1 - X4
MS
NS
9 10 11 12 13 14 15 16
OUT
IN
1 2 3 4 5 6 7 8
OUT
IN
X1
X3
1
1
16 1
16 1
X2
16
16
X4
12 1
X5
Product Manual IRB 2400 77
Connecting Signals Installation and Commissioning
Unit function Signal name
Out ch 1a
Out ch 1b
Out ch 2a
Out ch 2b
Out ch 3a
Out ch 3b
Out ch 4a
Out ch 4b
Out ch 5a
Out ch 5b
Out ch 6a
Out ch 6b
Out ch 7a
Out ch 7b
Out ch 8a
Out ch 8b
11
12
13
14
9
10
7
8
15
16
5
6
3
4
X1
Pin Customer conn.
1
2 supply
X2
Signal name Pin
Out ch 9a
Out ch 9b
1
2
Out ch 10a
Out ch 10b
Out ch 11a
Out ch 11b
5
6
3
4
Out ch 12a
Out ch 12b
Out ch 13a
Out ch 13b
Out ch 14a
Out ch 14b
Out ch 15a
Out ch 15b
Out ch 16a
Out ch 16b
11
12
13
14
9
10
7
8
15
16
78 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Unit function Signal name
Opto.
isol.
In ch 1
In ch 2
In ch 3
In ch 4
In ch 5
In ch 6
In ch 7
In ch 8
0V for in 1-8
Not used
Not used
Not used
Not used
Not used
Not used
Not used
12
13
14
15
16
9
10
7
8
11
5
6
3
4
X3
Pin Customer conn.
1
2
24 V
0 V
X4
Signal name Pin
In ch 9
In ch 10
1
2
In ch 11
In ch 12
In ch 13
In ch 14
5
6
3
4
In ch 15
In ch 16
0V for in 9-16
Not used
Not used
9
10
7
8
11
Not used
Not used
Not used
Not used
Not used
12
13
14
15
16
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting a source (PLC), sensitive to pre-oscillation current, a serial resistor
(100
Ω) may be used.
Product Manual IRB 2400 79
Connecting Signals Installation and Commissioning
3.16.9 Digital 120 VAC I/O DSQC 320
Technical data
See Product Specification IRB 2400, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
CONNECTION TABLE
Customer contacts: X1 - X4
Status
LED’s MS
NS
9 10 11 12 13 14 15 16
OUT
IN
1 2 3 4 5 6 7 8
OUT
IN
X1
X3
1
1
16 1
16 1
X2
16
16
X4
12 1
X5
80 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Unit function
Opto isol.
Out ch 4b
Out ch 5a
Out ch 5b
Out ch 6a
Out ch 6b
Out ch 7a
Out ch 7b
Out ch 8a
Out ch 8b
Signal name
Out ch 1a
Out ch 1b
Out ch 2a
Out ch 2b
Out ch 3a
Out ch 3b
Out ch 4a
11
12
13
14
9
10
7
8
15
16
5
6
3
4
X1 X2
Pin Customer conn.
Signal name Pin
1
2
AC supply Out ch 9a
Out ch 9b
1
2
Out ch 10a
Out ch 10b
Out ch 11a
Out ch 11b
5
6
3
4
Out ch 12a
Out ch 12b
Out ch 13a
Out ch 13b
Out ch 14a
Out ch 14b
Out ch 15a
Out ch 15b
Out ch 16a
Out ch 16b
11
12
13
14
9
10
7
8
15
16
Product Manual IRB 2400 81
Connecting Signals Installation and Commissioning
Unit function
Opto isol.
In ch 4b
In ch 5a
In ch 5b
In ch 6a
In ch 6b
In ch 7a
In ch 7b
In ch 8a
In ch 8b
Signal name
In ch 1a
In ch 1b
In ch 2a
In ch 2b
In ch 3a
In ch 3b
In ch 4a
13
14
15
16
9
10
11
12
7
8
5
6
X3 X4
Pin Customer conn.
Signal name Pin
1
2 N
AC In ch 9a
In ch 9b
1
2
3
4
In ch 10a
In ch 10b
3
4
In ch 11a
In ch 11b
In ch 12a
In ch 12b
7
8
5
6
In ch 13a
In ch 13b
In ch 14a
In ch 14b
In ch 15a
In ch 15b
In ch 16a
In ch 16b
13
14
15
16
9
10
11
12
82 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.17 Field bus units
3.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350
The RIO-unit can be programmed for 32, 64, 96 or 128 digital inputs and outputs.
The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable.
Technical data
See Product Specification IRB 2400, chapter 3.10 and Allen-Bradley RIO specification.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Customer terminals: X8 and X9
Signal name
LINE1 (blue)
X8
Pin
LINE2 (clear) shield 3 cabinet ground 4
1
2
Remote
I/O in
Signal name Pin blue clear shield
X9
1
2
3 cabinet ground 4
Remote
I/O out
X1
Device net input and ID connector
Not to be used
X1
X2
DSQC 350
X9
X8
ABB Flexible Atomation
RIO out
RIO in
Device Net connector X1, see section 3.16.3 on page 62
Figure 53 RIO-unit
Product Manual IRB 2400 83
Connecting Signals Installation and Commissioning
When the robot is last in a RIO loop, the loop must be terminated with a termination resistor according to Allen-Bradley’s specification.
This product incorporates a communications link which is licensed under patents and proprietary technology of
Allen-Bradley Company, Inc. Allen-Bradley Company, Inc. does not warrant or support this product. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation.
RIO communication concept
Allen Bradley control system
84
Robot 1 - 128 in / 128 out
Quarter 1
Quarter 2
128 in / 128 out
Quarter 3
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
Robot 2 - 64 in / 64 out
Quarter 1
64 in / 64 out
Quarter 2
Rack ID 13 (example)
Rack size 2
Starting quarter 1
Other systems
Quarter 1
Quarter 2
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack ID 13 (example)
Rack size 2
Starting quarter 3
Figure 54 RIO communication concept - Principle diagram
The Allen Bradley system can communicate with up to 64 external systems. Each of these systems is called a Rack and is given a Rack Address 0-63. Basically, each robot connected to the Allen Bradley system will occupy 1 rack.
Each rack is divided into 4 sections called Quarters. Each quarter provides 32 inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs.
A rack may also be shared by 2, 3 or 4 robots. Each of these robots will then have the same rack address, but different starting quarters must be specified.
The illustration above shows an example where Robot 1 uses a full rack while robot 2 and robot 3 share 1 rack.
The rack address, starting quarter and other required parameters such as baud rate, LED
Status etc. are entered in the configuration parameters.
The robot may communicate with the Allen Bradley system only, or be used in combination with I/O system in the robot. For example, the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment via general I/O addresses and the Allen Bradley system only reads the outputs as status signals.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
3.17.2 Interbus-S, slave DSQC 351
The unit can be operated as a slave for a Interbus-S system.
Technical data
See Interbus-S specification.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Unit ID to be entered in the Interbus-S master is 3. The lenght code depends on the selected data. Width between 1 and 4.
Customer terminals: see figure below regarding locations.
X20
Interbus-S in
X21
Interbus-S out
RC
BA
RBDA
POWER
CAN Rx
CAN Tx
MS
NS
POWER
X20
X21
X5 X3
X5-DeviceNet input and ID connector
X3
Interbus-S supply
Device Net connector X5, see section 3.16.3 on page 62
Figure 55 Interbus-S, DSQC 351
Product Manual IRB 2400 85
Connecting Signals Installation and Commissioning
Communication concept
128 in/128 out
64 in/64 out
Master PLC Robot 1
IN OUT
*1
IN OUT
*1
IN OUT
Figure 56 Outline diagram.
The Interbus-S system can communicate with a number of external devices, the actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
*1
Note that there is a link between pin 5 and 9 in the plug on interconnection cable which is connected to the OUT connector for each unit. The link is used to inform the Interbus-S unit that more units are located further out in the chain. (The last unit in the chain does not have cable connected and thereby no link).
Interbus-S IN
1
5
6
9
X20
Signal name Pin Description
TPDO1
TPDI1
1
2
Communication line TPDO1
Communication line TPDI1
GND
NC
NC
TPDO1-N
3
4
5
6
Ground connection
Not connected
Not connected
Communication line TPDO1-N
TPDI1-N
NC
NC
7 Communication line TPDI1-N
8 Not connected
9 Not connected
86 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Interbus-S OUT
5
1
9
6
X21
Signal name Pin Description
TPDO2
TPDI2
1
2
Communication line TPDO2
Communication line TPDI2
GND
NC
+5V
TPDO2-N
3
4
5
6
Ground connection
Not connected
+5VDC
Communication line TPDO2-N
TPDI2-N
NC
RBST
7 Communication line TPDI2-N
8 Not connected
9 Synchronization
X3
Interbus-S supply Signal name Pin Description
5 0 V DC
NC
1
2
External supply of Interbus-S
Not connected
1
GND
NC
+ 24 V DC
3
4
5
Ground connection
Not connected
External supply of Interbus-S
NOTE! External supply is recommended to prevent loss of fieldbus at IRB power off.
Product Manual IRB 2400 87
Connecting Signals Installation and Commissioning
3.17.3 Profibus-DP, slave, DSQC352
The unit can be operated as a slave for a Profibus-DP system.
Technical data
See Profibus-DP specification, DIN E 19245 part 3.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: IO Signals.
Circuit diagram, see chapter 11.
Customer connections
X20
Profibus connection
X20
PROFIBUS ACTIVE
NS
MS
CAN Tx
CAN Rx
POWER
X5 X3
88
X5 - DeviceNet connector
X3 - Power connector
Figure 57 DSQC352, location of connectors
Communication concept
Master PLC
Robot 1
Word 1:8
256 in/256 out
1
Word 9:16
*1
Figure 58 Profibus-DP communication concept
128 in/128 out
2
Robot 2
.11
Word 17:24
*1
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
The Profibus-DP system can communicate with a number of external devices. The actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs.
For application data, refer to Profibus-DP, International Standard, DIN 19245 Part 3.
*1 - Note that the Profibus cable must be terminated in both ends.
Profibus-DP
5
1
9
6
X20
Signal name Pin Description
Shield
NC
1
2
Cable screen
Not connected
RxD/TxD-P
Control-P
GND
+ 5V DC
3
4
5
6
Receive/Transmit data P
Ground connection
NC
Rxd/TxD-N
NC
7 Not connected
8 Recieve/Transmit data N
9 Not connected
X3
Profibus-DP supply Signal name Pin Description
5
0 V DC
NC
1
2
External supply of Profibus-DP
Not connected
1
GND
NC
+ 24 V DC
3
4
5
Ground connection
Not connected
External supply of Profibus-DP
Device Net connector X5, see section 3.16.3 on page 62.
Product Manual IRB 2400 89
Connecting Signals Installation and Commissioning
3.18 Communication
3.18.1 Serial links, SIO
The robot has two serial channels, which can be used by the customer to communicate
with printers, terminals, computers and other equipment (see Figure 59).
The serial channels are:
- SIO1-
RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 19 200 baud.
- SIO2-
RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 19 200 baud.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Product Specification IRB 2400, chapter 3.10.
Separate documention is included.when the option RAP Seriel link is ordered.
External computer
90
Figure 59 Serial channels, SLIP, outline diagram.
Customer terminals, on controller backplane:X1(SIO1) and X2(SIO2), see 3.7.
Two variants exits depending on backplane type.
Cable connectors with screwed connections (not supplied), type Phönix Combicon
MSTTBVA 2.5/12-6-5.08. Keying of board connector according to circuit diagram, chapter 11.
Product Manual IRB 2400
Installation and Commissioning Connecting Signals
DSCQ 330 (screw terminals)
9
10
7
8
11
12
5
6
3
4
X1
Pin
1
2
Signal
TXD
RTS N
0V
RXD
CTS N
0V
DTR
DSR
0V
DSQC 369 (D-sub connectors)
9
10
7
8
11
12
5
6
3
4
X2
Pin
1
2
Signal
TXD
TXD N
0V
RXD
RXD N
0V
DATA
DATA N
0V
DCLK
DCLK N
0V
5
6
3
4
X1
Pin
1
2
7
8
9
Signal
RXD
TXD
DTR
0 V
DSR
RTS N
CTS N
X2
Pin
1
2
3
4
5
6
7
8
9
Signal
TXD
TXD N
RXD
RXD N
0 V
DATA
DATA N
DCLK
DCLK N
Explanation of signals:
TXD=Transmit Data, RTS=Request To Send, RXD=Receive Data, CTS=Clear To
Send, DTR=Data Terminal Ready, DSR=Data Set Ready, DATA=Data Signals in Half
Duplex Mode, DCLK=Data Transmission Clock.
Product Manual IRB 2400 91
Connecting Signals Installation and Commissioning
C
O
N
S
O
L
E
LAN
TXD RXD
CAN
NS MS
A
U
I
3.18.2 Ethernet communication, DSQC 336
The ethernet communication board has two options for ethernet connection.
Connector X4 is used for connection of twisted-pair Ethernet (TPE), or as defined in
IEEE 802.3 : 10BASE-T. Maximum node-to-node distance 100 meter. The ethernet communication board has no termination for cable screen. Cable screen must be grounded at cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB.
Connector X11 is used for connection of transceivers with AUI (Attachment Unit Interface). Typical use of this connector is connection of transceivers for 10BASE2 (CheaperNet, Thinnet, Thinwire Enet, - 0.2 inch, 50 ohm coax with BNC connector) or optical fibre net. Note the environmental conditions for the transceiver inside the controller, i.e.
+70 o
C.
Technical data
See Ethernet specification.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
Separate documentation is included.when the option Ethernet services is ordered.
Customer terminals, on board front: X4 and X11
External computer Controller Robot 1 Controller Robot 2 etc...
X11 - AUI connection
F
T
P
E
DSQC
336
X4 - TPE connection
Ethernet HUB
Figure 60 Ethernet TCP/IP, outline diagram.
92 Product Manual IRB 2400
Installation and Commissioning Connecting Signals
Connector X4 - Ethernet TPE connector
1
8
X4
Signal name Pin Description
TPTX+
TPTX-
1
2
Transmit data line +
Transmit data line -
TPRX+
NC
NC
TPRX-
NC
NC
3
4
5
6
7
8
Receive data line +
Not connected
Not connected
Receive data line -
Not connected
Not connected
Connector X11 - Ethernet AUI connector
15
9
8
1
NC
GND
COLL-
TXD-
GND
RXD-
+12V
GND
NC
X11
Signal name Pin Description
GND
COLL+
1
2
Ground connection
Collision detection line +
TXD+
GND
RXD+
GND
3
4
5
6
Transmit data line +
Ground connection
Receive data line +
Ground connection
7
8
9
10
11
12
13
14
15
Not connected
Ground connection
Collision detection line -
Transmit data line -
Ground connection
Receive data line -
+12VDC
Ground connection
Not connected
Product Manual IRB 2400 93
Connecting Signals Installation and Commissioning
3.19 External operator’s panel
All necessary components are supplied, except for the external enclosure.
The assembled panel must be installed in a housing which satisfies protection class, IP 54, in accordance with IEC 144 and IEC 529.
45 o
196
70
M4 (x4)
M8 (x4)
193 223
Required depth 200 mm
180 224 240
62
96
Holes for flange
External panel enclosure
(not supplied)
140
184
200
Holes for operator’s panel
Teach pendant connection
Connection to the controller
100%
5 (x2)
Holes for teach pendant holder
90
155
Figure 61 Required preparation of external panel enclosure.
94 Product Manual IRB 2400
Installation and Commissioning Installing the Control Program
4 Installing the Control Program
The robot memory is battery-backed, which means that the control program and settings (pre-installed) are saved when the power supply to the robot is switched off.
The robot might be delivered without software installed and the memory back-up batteries disconnected to ensure maximum battery capacity after installation.
If so, connect the batteries and start the installation according to 4.1.1.
4.1 System diskettes
• Key disk (one disk)
Each robot needs an unique key disk with selected options and IRB type.
Robots within the same family (i.e. different variants of the robot) can use the same key disk with a licence number.
• System pack
BaseWare OS, all options and ProcessWare.
• Controller parameters (one disk)
At delivery, it includes I/O configuration according to order specification.
At commissioning all parameters are stored.
• Manipulator parameters (one disk)
Includes sync. offsets from manufacturing calibration.
4.1.1 Installation procedure
1. Perform a cold start on the system.
2. Insert the “Key disk” when displayed on the teach pendant.
3. Follow information displayed on the teach pendant. Keep attention to prompted
System pack disk number (all diskettes are not used at the same installation).
During the installation following menus appears:
- Silent = The installation follows the information on the Key disk.
- Add Opt =The installation follows the Key disk but further options, not included in the system pack, are possible to add.
- Query = Questions about changing language, robot type (within the same family), gain access to service mode, see User’s Guide, System
Parameters etc. are coming up. Makes it possible to exclude options but not add more than included in the Key disk.
If Query is selected, make sure that the correct robot type is entered. If not, this will affect the safety function Reduced speed 250 mm/s.
Product Manual IRB 2400 95
Installing the Control Program Installation and Commissioning
If Query is selected, make sure that all required options are installed. Note that some of these options also require installation of other options. Rejecting of proposed options during installation may cause an incomplete robot installation.
4. The robot performs a warm start when installation is finished.
Wait until the welcome window appears on the display before doing anything. The warm start can take up to 2 minutes after the installation display ready.
5. Load the specific installation parameters from the Controller Parameter disk or corresponding.
After the control program has been installed, the diskettes should be stored in a safe place in accordance with the general rules for diskette storage. Do not store the diskettes inside the controller to avoid damaged from heat and magnetic fields.
6. Conclude the installation with updating the revolution counters according to section
4.2 Calibration of the manipulator
Calibrate the manipulator according to section 2.16.
4.3 Cold start
To install the control program in a robot already in operation the memory must be emptied. Besides disconnecting the batteries for a few minutes, the following method can be used:
1. Select the Service window
2. Select File: Restart
3. Then enter the numbers 1 3 4 6 7 9
4. The fifth function key changes to C-Start (Cold start)
5. Press the key C-Start
It will take quite some time to perform a Cold start. Just wait until the robot starts the
Installation dialog, see 4.1.1.
Do not touch any key, joystick, enable device or emergency stop until you are prompted to press any key.
96 Product Manual IRB 2400
Installation and Commissioning Installing the Control Program
4.4 How to change language, options and IRB types
(Valid for robots within the same family)
1. Select the Service window
2. Select File: Restart
3. Enter the numbers 1 4 7
4. The fifth function key changes to I-Start
Note!
Make sure that the disk 3 from the System pack is inserted when installing BaseWare
OS Plus or disk 5 when installing BaseWare OS.
5. Press the key I-Start
6. Continue with following the text on the teach pendant.
Question about used DC-links and balancing units
You will get a question about used DC-link, below there is a list of avaible DClinks.You will find the article number for the DC-link on the unit inside the controller.
Type
DSQC 345A
DSQC 345B
DSQC 345C
DSQC 345D
DSQC 358C
DSQC 358E
Art. no.
3HAB 8101-1
3HAB 8101-2
3HAB 8101-3
3HAB 8101-4
3HAB 8101-10
3HAB 8101-12
Config id
DC0
DC1
DC2
DC3
DC2T
DC2C
Description
DC-link
DC-link
DC-link
DC-link, step down
DC-link + single drive unit
DC-link + single drive unit
For IRB 6400 you will also get a question on what type of balancing units that is used.
For identification, please see label attached at the top of the units.
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Installing the Control Program Installation and Commissioning
4.5 How to use the disk, Manipulator Parameters
The S4C controller does not contain any calibration information at delivery (Robot Not
Calibrated shown on the teach pendant).
Once the Manipulator Parameter disk contents has been loaded to the controller as in one of the two cases described below, should a new parameter back-up be saved on the disk, Controller Parameter.
After saving the new parameters on the disk, Controller Parameter the
Manipulator Parameter disk is no longer needed.
4.6 Robot delivered with software installed
In this case the basic parameters are already installed.
Load the calibration offset values from the disk, Manipulator Parameters.
1. Select File: Add or Replace Parameter.
Do not select Add new or Load Saved Parameters.
2. Press OK.
3. Save the new parameters according to section 4.8.
4.7 Robot delivered without software installed
In this case a complete cold start is necessary, remember to connect the back-up batteries.
The basic parameters are loaded at the cold start. The delivery specific I/O configuration is loaded from the disk, Controller Parameters.
1. Select File:Add New Parameters.
2. Press OK.
3. Load the calibration offset values from the disk, Manipulator Parameters.
4. Select File:Add or Replace Parameter.
Do not select Add new or Load Saved Parameters.
5. Press OK.
6. Save the new parameters according to section 4.8.
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Installation and Commissioning Installing the Control Program
4.8 Saving the parameters on the Controller Parameter disk
1. Insert the disk, Controller Parameter.
2. Select File:Save All As.
For more detailed information regarding saving and loading parameters see User’s
Guide, System Parameters.
Product Manual IRB 2400 99
Installing the Control Program Installation and Commissioning
100 Product Manual IRB 2400
Installation and Commissioning External Axes
5 External Axes
5.1 General
External axes are controlled by internal or external (equals to non ABB) drive units.
Internal drive units are mounted either inside the robot cabinet or in a separate external cabinet. External drive units are mounted in a user designed cabinet.
A maximum number of 6 external axes can be controlled by S4C. Internal drive units mounted in a separate cabinet cannot be combined with external drive units.
The drive and measurement systems each consist of two systems. Each system is connected to the CPU boards via a serial communication link.
A number of template configuration files are supplied with the system. The configuration files are optimum designed concerning system behaviour and performance of the axes. When installing external axes it is important to design installations, so a combination of standard files can be used.
Axes connected to Measurement System 1 can use Drive System 2 and vice versa.
Allowed combinations - see configuration files section 5.3.5.
Product Manual IRB 2400 101
External Axes Installation and Commissioning alt.
Contains no
CPU
Measurement System 2
Drive System
1, inside robot cabinet
102
Drive System 2 inside external axes cabinet
Drive System 2 inside user designed cabinet
(non ABB drives)
Measurement
System 1
Figure 62 Outline diagram, external axes.
One extra serial measurement board (SMB) can be connected to Measurement System
1 and up to four to Measurement System 2. See Figure 62. One of the extra serial
measurement boards of system 2 can be located inside the robot cabinet.
Max one external axis can be connected to Drive System 1. This axis is connected to the drive unit located in the DC-link. Up to six external axes can be connected to Drive
System 2. Drive System 2 is in most cases located in a separate external cabinet.
For robots using only two drive units, as IRB1400 and IRB2400, a drive system 2 can be located in the robot cabinet. This mixed system is called Drive System 1.2 . Two axes can be connected to the drive module. In this case no external drive units or internal drive units mounted in a separate cabinet can be used.
Product Manual IRB 2400
Installation and Commissioning External Axes
5.2 Easy to use kits
A number of easy to use kits are available by ABB Flexible Automation AB. These kits contain all parts needed to install and operate external axes.
The kit contains:
- Motor/motors with brake and resolver. Different sizes of motors available.
- Gear boxes.
- Connection box with serial measurement board, manual brake release and terminal block for limit switches.
- All cables with connectors.
- Configuration file for easy software installation.
- Documentation
For more information see Product Specification Motor Unit from ABB Flexible Automation documentation.
Product Manual IRB 2400 103
External Axes Installation and Commissioning
5.3 User designed external axes.
5.3.1 DMC-C
.
Atlas Copco Controls stand alone servo amplifier DMC-C can be connected to Drive
System 2, see Figure 63. Total of max 6 external axes can be installed.
Drive System 2
Mesurement
System 2
Atlas DMC
Atlas Copco
Atlas DMC
Atlas Copco
Atlas DMC
Atlas Copco
104
Serial measurement board
Figure 63 Servo amplifier, DMC.
Atlas Copco Controls provides the information on suitable motors and how to make installation and commissioning,
Product Manual IRB 2400
Installation and Commissioning External Axes
5.3.2 FBU
Atlas Copco Controls FBU (Field Bus Unit) can handle up to 3 external drive units, see
Drive System 2
Mesurement System 2
Atlas DMC
Atlas Copco
S
E
R
V
O
S
E
R
V
O
S
E
R
V
O
Serial measurement board
Figure 64 Field bus unit, FBU.
The drive units can be connected to analog speed reference outputs (+/- 10 V) or a field bus.
For further information about DMC-C and FBU contact Atlas Copco Controls.
Product Manual IRB 2400 105
External Axes Installation and Commissioning
106
5.3.3 Measurement System
There are two measurement system systems, 1 and 2. Each system is connected to the
CPU board via a serial link. The serial link is of ring type with board 1 connected to
CPU-board serial output. The last Serial Measurement Board (SMB) is connected to the
CPU-board serial input.This link also supplies power to the SMB.
Measurement System 1 can consist of up to two SMB, one used for the robot manipulator, the other one for one external axis, normally a track motion. The external axis must be connected to node 4 and in the configuration file be addressed as logical node
7.
Measurement System 2 can consist of one to four SMB boards. The board numbering always starts with board 1. No gaps may occur in the number sequence. Every axis connected to a measuring system must have an unique node number. While the node number is the same as physical connection, the physical connection node must also be unique.
Each SMB has 6 connection nodes for resolvers. A battery supplies the SMB with power during power fail. If the axes move during power fail the internal revolution counters are automatically updated. After power on the system is ready for operation without any synchronization procedure.
A special configuration can be used with no robot connected. Only Measurement System 1 with one or two SMB may be used. Up to 6 external axes can be connected to
those boards. See configuration files in Figure 78.
MEASUREMENT SYSTEM 1 configuration files MN4M1Dx
Robot manipulator
Serial
Measurement
Board 1
6 resolvers
Serial
Measurement
Board 2 node 4
1 resolver
CPU
Measurement
System 1
serial communication
MEASUREMENT SYSTEM 2 configuration files MNxM2Dx
Serial
Measurement
Board 1
CPU
Measurement
System 2
serial communication
Serial
Measurement
Board 2
Serial
Measurement
Board 3
Serial
Measurement
Board 4
Max 6 resolvers
(5 if one axis connected to
Measurement
System 1)
Figure 65 Measurement systems.
Product Manual IRB 2400
Installation and Commissioning
MEASUREMENT SYSTEM 1 (only external axes, no robot) configuration files ACxM1D1
(Measurement System 2 may not be used together with this configuration)
CPU
Serial
Measurement
Board 1
Serial
Measurement
Board 2
Measurement
System 1
serial communication
Max 6 resolvers
External Axes
Figure 66 Measurement system 1.
Resolver
Each resolver contains two stators and one rotor, connected as shown in Figure 67.
EXC*
0v EXC*
Stator X
Rotor
X*
0V X*
* See connection table
Stator Y
Y*
0V Y*
Figure 67 Connections for resolvers.
Technical data
Resolver
Motor to resolver gear ratio
Resolver cable length:
Integrated in motor of IRB type or art.no. 5766 388-5, size 11
Resolver must be approved by ABB for reliable operation.
1:1, direct drive max 30 m (X, Y for each resolver) total max 70 m for EXC signals.
Product Manual IRB 2400 107
External Axes Installation and Commissioning
Cable: AWG 24, max 55pF/m, with shield.
The X, Y, 0V X and 0 V Y signals are used to connect resolvers to a serial measurement board.
The EXC, 0V EXC are used for common supply for all resolvers, parallel connected.
It is very important that the noise level on the measurement signals from the external axes is kept as low as possible, to prevent bad performance. Correct shielding and ground connections of cables, measurement boards and resolvers is essential.
The cabling must comply with signal class “measurement signals” (see chapter 3.1,
Signal classes).
The enclosure for external serial measurement board(s) must comply with enclosure class IP 54, in accordance with IEC 144 and IEC 529.
Resolver, connector on robot cabinet wall (option: 386 - External Axes Measurement
Board, mounted inside robot cabinet)
XS27, Measurement System 2, board 1
EXC1
0 V
EXC1
EXC2
0 V
EXC2
X
Y
0V X
0V Y
Node 1 Node 2 Node 3 Node 4 Node 5 Node 6
A1 A3 A5
A2
B1
C1
B2
C2
A4
B3
C3
B4
C4
A6
B5
C5
B6
C6
A8
A9
B8
C8
B9
C9
A10
A11
B10
C10
B11
C11
A12
A13
B12
C12
B13
C13
108 Product Manual IRB 2400
Installation and Commissioning External Axes
Resolver, connectors on Measurement Board DSQC 313
Contact/ point
16
17
18
19
20
11
12
13
14
15
21
22
23
24
25
8
9
6
7
10
3
4
1
2
5
R2.G
+BAT
0V BAT
R2.SMB
D-Sub 9 pin
GND
BATLD
0V
SDO-N
SDI-N
+BATSUP
+24V
SDO
SDI
R2.SMB
1-2
D-Sub 15 socket
GND
0V EXC1
0V EXC1
Y2
X2
Y1
X1
-
EXC1
EXC1
R2.SMB
1-4
D-Sub 25 pin
GND
X1
Y1
X2
Y2
0V EXC1
0V EXC1
0V EXC1
X3
Y3
0V Y2
0V X2
0V Y1
0V X1
X4
Y4
0V EXC2
0V X1
0V Y1
0V X2
0V Y2
EXC1
EXC1
EXC1
R2.SMB
3-6
D-Sub 25 socket
GND
X4
Y4
X5
Y5
0V EXC2
0V EXC2
0V EXC2
X6
Y6
X3
Y3
0V EXC1
0V X4
0V Y4
0V X3
0V Y3
0V X4
0V Y4
EXC2
0V X5
0V Y5
EXC2
EXC2
EXC2
0V X6
0V Y6
0V X3
0V Y3
EXC1
Product Manual IRB 2400 109
External Axes Installation and Commissioning
110
R2.SMB
R2.G
R2.SMB 1-4 R2.SMB 3-6
Serial Measurement Board (SMB)
R2.SMB 1-2
SDO serial communication output
SDI
+BAT serial communication input battery +
0V BAT battery 0 V
BATLD not to be used
BATSUP not to be used
+24 V 24 V power
0 V 0 V power
EXC1 excitation power to resolver 1,2,3
EXC2 excitation power to resolver 4,5,6
X1 Input x-stator node 1
5.3.4 Drive System
There are two drive systems 1 and 2. Each system is connected to the CPU board via a serial link. The link also supplies low voltage logic power to the rectifier and drive modules.
Each drive system has its own transformer. For information on fuses, power contactors etc. see documentation for the separate enclosure.
The rectifier DSQC 358C has in addition to its rectifier section also a drive inverter for one external axis. This rectifier can be used in all S4C robot cabinets except for those robots needing the DSQC 345D rectifier.
For robots using two drive units, an extra drive unit can be placed in the S4C robot cabinet. This drive unit is connected to the Drive System 2 serial communication link, but use the Drive System 1 rectifier. This combined system is called Drive System 1.2 .
If drive unit with three drive inverters (nodes) are used, axes with measurement node
1, 2, 3 or 4, 5, 6 may not be connected to the same drive unit.
If the function “common drive” is to be used, a contactor unit for motor selection is required.
As an option it’s possible to use Atlas DMC of FBU. Those units are always connected to drive system 2 and measurement system 2. They CANNOT be combined with internal controlled drive units connected to drive system 2. Up to 6 external axis can be con-
nected using DMC:s and/or FBU:s. In section 5.3.5 there is a complete list of template
files for external controlled axes.
Product Manual IRB 2400
Installation and Commissioning External Axes
When designing the drive system following has to be checked:
• Max motor current, in order not to demagnetize the motor.
• Max/rated current from drive inverter.
• Max/rated current from drive unit (sum of all inverters on same drive unit)
• Max/rated current from dc-link
• Max/rated power for bleeder
• Max/rated power from transformer
Note: If the system contains axes with no stand by state (the axes will continue to be controlled while the brakes are activated for the robot), the max allowed power consumption of these axes are 0.5 kW.
Note:
For safety reasons, the power supply to the external motor must be switched off when the robot is in the MOTORS OFF mode.
Drive system configuration with one external axis at Drive System 1 in S4C robot cabinet and five to six axes at Drive System 2 installed in external cabinet.
DRIVE SYSTEM 1
Drive System 1 serial communication
DRIVE SYSTEM 2
Drive System 2 serial communication
External axis drive system 1
(1 axis)
Unit number 0 3 2 1
Transformer 1
Robot axes
Figure 68 Drive systems with external cabinet.
Unit number 0* 3* 2* 1*
Transformer 2
External axes drive system 2
(5-6 axes)
Product Manual IRB 2400 111
External Axes Installation and Commissioning
Drive system configuration with one external axis at Drive System 1 and two or three axes at Drive system 2, all installed in the S4C robot cabinet.
DRIVE SYSTEM 1.2
Drive System 2 serial communication
Drive System 1 serial communication
DC-link
(optional with driver inverter)
Drive unit
* Unit number for drive system 2
External axis drive system 1
(1 axis)
Unit number 0 0* 2 1
Transformer 1
Robot axes
External axis drive system 2
(2-3 axes)
Figure 69 Drive system installed in the S4C cabinet.
Technical data Drive System
Max current
(A)
DSQC 345C / DC2
DSQC 358C / DC2T
DSQC 358E / DC2C
DSQC 345D / DC3
80
70
Figure 70 Rectifier units.
Rated current
(A)
Max bleeder power
(kW)
Rated bleeder power
(kW)
Min voltage
(V)
14.6
16.7
15.3
15.3
0.9
0.9
275
370
112 Product Manual IRB 2400
Installation and Commissioning External Axes
Unit type
DSQC 346A
DSQC 346B
DSQC 346C
DSQC 346G
DSQC 358C
DSQC 358E
Node 1
3.25/1.6 A
6.7/3.2 B
11.3/5.3 C
Node 2 Node 3
3.25/1.6 A 1.5/1.0 D
29.7/16.5 G 36.8/20.0 T
36.8/20.0 T
11.3/5.3 C
Total unit
8.0/4.2
3.25/1.6 A 1.5/1.0 D 11.45/5.8
11.3/5.3 C 6.7/4.0 B 29.3/12.1
66.5/30.0
36.8/20.0
11.3/5.3 C
Figure 71 Drive units, max. current (A RMS)/average current (A RMS).
Pin Node Phase
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
1 1 1
- - 3
- - 3
- - 3
2 2 2
W V U
- - W
- - V
- - U
W V U
Figure 72 Power connections, drive unit DSQC 346A, B, C X2
Pin Node Phase
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
1 1 1
1 1 1
2 2 2
2 2 2
2 2 2
U V W
U V W
U U U
V V V
W W W
Figure 73 Power connections, drive unit DSQC 246G
Pin ,Node Phase
X2
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
- - -
- - -
2 2 2
2 2 2
2 2 2
- - -
- - -
U U U
V V V
W W W
Figure 74 Power connections, drive unit DSQC 358C, E X2
Product Manual IRB 2400 113
External Axes Installation and Commissioning
Motor connection to drive unit, external connector
Motor current R-phase (U-phase), S-phase (V-phase) and T-phase (W-phase) respectively.
Technical data
Motor
Technical data AC synchronous motor
3-phase, 4 or 6-pole
ABB Flexible Automation can supply further information.
EXT PTC
This signal monitors the temperature of the motor. A high resistance or open circuit indicates that the temperature of the motor exceeds the rated level. If a temperature sensor is not used, the circuit must be strapped. If more than one motor is used, all PTC resistors are connected in series.
XS7 Controller
R (U)
S (V)
T (W)
EXT PTC
0 V EXT PTC
0V EXT BRAKE
EXT BRAKE REL
EXT BRAKE PB
PTC
Brake
Motor
Manual brake release
Figure 75 Connections of motor.
114 Product Manual IRB 2400
Installation and Commissioning External Axes
14
15
16
10
11
12
13
8
9
XS7, Connector on S4C robot cabinet wall (option: 391/392/394.)
Conn. Point
1
2
3
6
7
4
5
D
0V EXT PTC
EXT PTC
-
PTC jumper 1
PTC jumper 1
C
M7 T
M7 T
M7 T
PTC jumper 2
PTC jumper 2
M8 T
M8 T
B
M7 S
M7 S
M7 S
LIM 2A
LIM 2B
M8 S
M8 S
BRAKE
REL
0V BRAKE
A
M7 R
M7 R
M7 R
LIM 1A
LIM 1B
M8 R
M8 R
BRAKE
REL
BRAKE
REL
0V BRAKE 0V BRAKE BRAKE PB
M9 T M9 S M9 R
M9 T
M9 T
M9 S
M9 S
M9 R
M9 R
Figure 76 Motor connections.
OPTION 391
M7
Drive system
1
Drive Unit Drive node Node type
0 2 T
OPTION 392
M7
M8
OPTION 394
M7
M8
M9
Drive system Drive Unit Drive node Node type
2
2
Drive system
1
2
2
0
0
Drive Unit Drive node Node type
0
0
0
2
1
2
1
2
T
G
T
G
T
Product Manual IRB 2400 115
External Axes Installation and Commissioning
X7, Connector on external cabinet wall (options: 37x)
8
9
14
15
16
10
11
12
13
Conn. Point
1
2
3
6
7
4
5
D
0V EXT PTC
EXT PTC
-
PTC jumper 1 PTC jumper 2
PTC jumper 1 PTC jumper 2
M10 R
M10 R
M10 S
M10 S
-
M12 R
M12R
M12 S
M12 S
M12 T
M12 T
C
M7 T
M7 T
M7 T
M8 T
M8 T
M10 T
M10 T
B
M7 S
M7 S
M7 S
LIM 2A
LIM 2B
M8 S
M8 S
BRAKE
REL
0V BRAKE
0V BRAKE 0V BRAKE BRAKE PB
M9 T M9 S M9 R
M9 T
M9 T
M9 S
M9 S
M9 R
M9 R
M11 T
M11 T
M11 T
M11 S
M11 S
M11 S
M11 R
M11 R
M11 R
A
M7 R
M7 R
M7 R
LIM 1A
LIM 1B
M8 R
M8 R
BRAKE
REL
BRAKE
REL
OPTION 37M : axes M7-M8
OPTION 37N : axes M7-M10
OPTION 37O : axes M7-M12
M7
M8
M9
M10
M11
M12
Drive systemDrive UnitDrive node Node type
2
2
1
1
2
1
T
G
2
2
2
2
2
2
3
3
2
1
2
1
T
G
T
G
116 Product Manual IRB 2400
Installation and Commissioning External Axes
OPTION 37P : axes M7-M9
OPTION 37Q : axes M7-M12
M7
M8
M9
M10
M11
M12
Drive systemDrive UnitDrive node Node type
2 1 1 C
2
2
2
2
2
1
1
2
2
2
OPTION 37V : axes M7-M10
OPTION 37X : axes M7-M12
2
3
1
2
3
C
B
C
C
B
M7
M8
M9
M10
M11
M12
Drive systemDrive UnitDrive node Node type
2
2
1
1
1
2
C
C
2
2
2
2
2
2
3
3
2
1
2
1
T
G
T
G
Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury.
Note:
For safety reasons, the power supply to the external motor must be switched off when the robot is in the MOTORS OFF mode.
5.3.5 Configuration Files
In order to simplify installation of external axes a number of configuration files are delivered with the system. The configuration files are optimum designed concerning system behaviour and performance of the axes. When installing external axes it is important to design installations, so a combination of existent files can be used.
Four types of configuration files are delivered:
• Utility files for defining transformer and rectifier types in drive system 2.
• External axes files used for axes connected to a system with robot. File names
MNxMyDz (Measurement Node x, Measurement system y, Drive system z),
• External controlled external axis. File names ENxM2D2 (External Node x,
Measurement system 2, Drive system 2), see Figure 79.
• External axes files used in system without robot. File names ACxMyDz
(Axis Controlled x, Measurement system y, Drive system z), see Figure 78.
Product Manual IRB 2400 117
External Axes Installation and Commissioning
For installing and change of parameter data, see the User’s Guide, section System Parameters, Topic: Manipulator.
In order to have the possibility to read and change most of the parameters from the teach pendent unit, the system must be booted in service mode.
118 Product Manual IRB 2400
Installation and Commissioning External Axes
Configuration file Logical axis
MN4M1D1
MN4M1D2
MN4M1D12
7
7
7
1
1
Measuring system
System* Node*
1
4(7)**
4(7)**
4(7)**
2
2
System*
1
Drive system
Unit position Node
0
1
0
2
2
2
MN1M2D1
MN1M2D2
MN1M2D12
MN2M2D1
MN2M2D2
MN2M2D12
8
8
8
9
9
9
2
2
2
2
2
2
1
1
1
2
2
2
1
2
2
1
2
2
0
1
0
0
2
0
2
2
2
2
1
1
MN3M2D1
MN3M2D2
MN3M2D12
MN4M2D1
MN4M2D2
MN4M2D12
MN5M2D1
MN5M2D2
MN5M2D12
MN6M2D1
MN6M2D2
MN6M2D12
10
10
10
11
11
11
12
12
12
7
7
7
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
Figure 77 Configuration files with default data.
Product Manual IRB 2400
1
2
2
1
2
2
1
2
2
1
2
2
2
2
2
2
1
1
2
2
2
2
1
1
0
1
0
0
3
0
0
3
0
0
2
0
119
External Axes Installation and Commissioning
* Parameter value must not be changed.
** Is connected physically to node 4 but the logical value in the system parameters must be 7.
Logical axis is used as the axis number in the RAPID instruction and for the teach pendent. Normally the robot use axes 1-6 and the external axes 7-12. The user can change the logical axis number to fit the new application. Only axes with unique axis numbers may be active at the same time.
If drive units with three inverters are used, note the limitation described under drive system.
Configuration file
Logical axis Measuring system Drive system
AC1M1D1 7
AC2M1D1 8
AC3M1D1 9
AC4M1D1 10
AC5M1D1 11
AC6M1D1 12
1
1
1
1
1
System* Node* System* Unit position
1 1 1 1
2
3
1
1
2
3
4
5
6
1
1
1
2
3
1
Configuration file
EN1M2D2 8
EN2M2D2 9
EN3M2D2 10
EN4M2D2 11
EN5M2D2 12
EN6M2D2 13
Figure 78 Configuration files with default data.
Logical axis
Measuring system
System* Node*
2
2
2
2
2
12
1
2
3
4
5
6
2
2
2
2
2
2
System*
0
1
2
3
4
5
Drive system
Unit position Node
1
1
1
1
1
1
1
1
1
2
2
Node
2
Figure 79 Configuration files with default data.
Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury.
120 Product Manual IRB 2400
Maintenance
CONTENTS
Page
2.3 Changing the battery in the measuring system ............................................... 4
2.4 Changing filters/vacuum cleaning the drive-system cooling .......................... 6
2.6 Changing the battery for memory back-up ..................................................... 6
Product Manual IRB 2400 1
Maintenance
CONTENTS
Page
2 Product Manual IRB 2400
Maintenance
Maintenance
The robot is designed to be able to work under very demanding circumstances with a minimum of maintenance. Nevertheless, certain routine checks and preventative maintenance must be carried out at given periodical intervals, see the table below.
• The exterior of the robot should be cleaned as required. Use a vacuum cleaner or wipe it with a cloth. Compressed air and harsh solvents that can damage the sealing joints, bearings, lacquer or cabling must not be used.
• The control system is completely encased which means that the electronics are protected in any normal working environment. In very dusty environments, nevertheless, the interior of the cabinet should be inspected at regular intervals. Use a vacuum cleaner if necessary. Change filter according to prescribed maintenance.
• Check that the sealing joint and cable bushings are really airtight so that dust and dirt are not sucked into the cabinet.
1 Maintenance intervals
MANIPULATOR
Prescribed maintenance
Check twice a year
Maintenance intervals, time in operation
4000 hrs
(1 year with two shift)
12 000 hrs
(3 years with two shift)
Others
3 years
1
Measuring system
Change battery
Change the signal cabling upper arm, if option 04y
X
Mechanical stop axis 1
Have to be changed if bent.
Wrist unit
Change oil
X
2
X
3
5 years
CONTROLLER
Memory back-up
Change battery
Filter for drive-system cooling
X
5
5 years
2. Change for the first time after 1 year or 4000 hours, after that every five years.
3. Is only needed if the robot is working in an enviroment temperature over 40 o
C.
5. Change interval strongly dependent on environment around the control system. An extra dust filter for the cooling device is supplied with the robot.
4
Product Manual IRB 2400 3
Maintenance
2 Instructions for Maintenance
2.1 Oil in gears
The gearboxes for axes 1, 2, 3 and 4 are lubricated for life with oil, which corresponds to 40 000 hours in operation.
Oil in gearboxes 5 and 6 must be changed at the intervals specified in the maintenance table. The oil is checked and changed as described in the chapter Repairs, section Oil change in gearboxes.
2.2 Signal cabling upper arm
The cabling must be changed at intervals specified in the maintenance table. The cabling is changed as described in the chapter Repairs, section Cabling and Measuring board.
2.3 Changing the battery in the measuring system
The battery to be replaced is located in the base (see Figure 1).
The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4.
The battery must never be just thrown away; it must always be handled as hazardous waste.
• Set the robot to the MOTORS OFF operating mode. (This means that it will not have to be coarse-calibrated after the battery change.)
• Loosen the battery terminals from the serial measuring board and cut the clasp that keep the battery unit in place.
• Install a new battery with a clasp and connect the terminals to the serial measuring board.
4 Product Manual IRB 2400
Maintenance
• The battery takes 36 hours to recharge; the mains supply must be switched on during this time and there must not be any power interrupts.
Remove the cover to get access to the battery.
Figure 1 The battery is located in the base.
Alternative battery
As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed.
The lithium battery needs no charging and has for that reason a blocking diode which prevents charging from the serial measurement board.
The benefit with a lithium battery is the lifetime, which can be up to 5 years in service, compare with the Ni-Cd battery’s max life time of 3 years in service.
Two lithium batteries exists:
- a 3-cell battery, art.no. 3HAB 9999-1
- a 6-cell battery, art.no. 3HAB 9999-2
The life time of the lithium battery depends on how frequently the user switches off the power. The estimated max life time in years for the different lithium batteries and the recommended exchange interval is shown below:
User type:
1. Vacation (4 weeks) power off
Exchange 3-cell: Exchange 6-cell: every 5 years every 5 years*
2. Weekend power off + user type 1 every 2 years
3. Nightly power off + user type 1 and 2 every year every 4 years every 2 years
* Because of material ageing the maximum life time in service is 5 years.
Voltage of batteries, measured at power off:
Ni-Cd
Lithium
Min
7.0 V
7.0 V
Max.
8.7 V
-
Exchange of the battery is done according to the first section of this chapter.
Product Manual IRB 2400 5
Maintenance
2.4 Changing filters/vacuum cleaning the drive-system cooling
The article number of the filter is 3HAB 8028-1.
• Loosen the filter holder on the outside of the door by moving the holder upwards.
• Remove the old filter and install a new one (or clean the old one and re-install it).
• When cleaning, the rough surface (on the clean-air side) should be turned inwards.
Clean the filter three or four times in 30-40° water with washing-up liquid or detergent. The filter must not be wrung out, but should be allowed to dry on a flat surface.
Alternatively, the filter can be blown clean with compressed air from the clean-air side.
• If an air filter is not used, the entire cooling duct must be vacuum cleaned regularly.
2.5 Checking the mechanical stop, axis 1
Check regularly, as follows:
Stop pin:
- that the pin is not bent.
If the stop pin is bent, it must be replaced by a new one.
The article number of the pin is 3HAB 6687-1
2.6 Changing the battery for memory back-up
Type: Lithium Battery.
The article number of the battery is 3HAB 2038-1
The batteries (two) are located under the top cover to the right, at the top of the rear wall
6 Product Manual IRB 2400
Maintenance
.
Plan view
Front view
Warning:
• Do not charge the batteries. An explosion could result or the cells could overheat.
• Do not open, puncture, crush, or otherwise mutilate the batteries. This could cause an explosion and/or expose toxic, corrosive, and inflammable liquids.
• Do not incinerate the batteries or expose them to high temperatures. Do not attempt to solder batteries. An explosion could result.
• Do not connect positive and negative terminals.
Excessive heat could build up, causing severe burns.
Warning:
Do not incinerate or dispose of lithium batteries in general waste collection, as there is a risk of explosion. Batteries should be collected for disposal in a manner that prevents short circuitting, compacting, or destruction of case integrity and the hermetic seal.
Figure 2 The location of the batteries on the computer unit.
• Note from the teach pendant which of the two batteries has expired and needs replacement.
• Loosen the expired battery terminal from the backplane.
• Remove the battery by loosening the clasps.
• Insert the new battery and fasten the clasps.
• Connect the battery terminal to the backplane.
• If both batteries must be replaced, make sure that the power is on. If not all memory content will be erased. A complete new installation of Robot Ware and parameters is then necessary, see Installation and Commissioning.
Product Manual IRB 2400 7
Maintenance
2.7 RAM Battery lifetime
The maximum service lifetime of the battery is five years. The lifetime is influenced by the installed memory board type and by the length of time the system is without power.
The following table indicates the minimum time, in months, that memory will be held if the system is without power:
Memory board size
4 MB
6 MB
8 MB
16 MB
First battery
6
5
6.5
5
Both batteries
12
10
13
10
A battery test is performed during the following occasions:
1. System diagnostics (before software installation). Failing test results in one of the following messages on the display:
- “Warning: Battery 1 or 2 < 3.3V” i.e. one of the batteries is empty.
- “Error: Battery 1 and 2 < 3.3V” i.e. both batteries are empty.
2. Warm start. Failing test results in one of the following messages on the display:
- 31501 Battery voltage too low on battery 1.
- 31502 Battery voltage too low on battery 2.
- 31503 Battery voltage too low on both batteries.
8 Product Manual IRB 2400
Troubleshooting Tools
CONTENTS
Page
1.2.1 Entering the test mode from the teach pendant ...................................
1.2.2 Console connected to a PC ..................................................................
2.4 Memory board DSQC 324/16Mb, 323/8Mb, 317/6 Mb, 321/4MB................ 15
2.10 Remote I/O DSQC 350, Allen Bradley......................................................... 22
Product Manual 1
Troubleshooting Tools
CONTENTS
Page
2 Product Manual
Troubleshooting Tools
Troubleshooting Tools
Generally speaking, troubleshooting should be carried out as follows:
• Read any error messages shown on the teach pendant display.
What these messages mean is described in System and Error Messages.
• Check the LEDs on the units. See Indication LEDs on the Various Units page 14.
• Switch the power off and then on. When the robot is started up, a self diagnostic is run which detects any errors. The tests performed during the self diagnostic are
described in the chapter Diagnostics page 3.
• Check the cables, etc., with the help of the circuit diagram.
1 Diagnostics
The control system is supplied with diagnostic software to facilitate troubleshooting and to reduce downtime. Any errors detected by the diagnostics are displayed in plain language with an code number on the display of the teach pendant.
All system and error messages are logged in a common log which contains the last 50 messages saved. This enables an “error audit trail” to be made which can be analysed.
The log can be accessed from the Service window using the teach pendant during normal operation and can be used to read or delete the logs. All system and error messages available are listed in User’s Guide.
The diagnostic programs are stored in flash PROM on the robot computer board. The diagnostic programs are executed by the I/O computer.
The control system runs through various tests depending on the start up mode:
Cold Start -
Cold starts occur normally only when the control system is started the first time, or when any computer board has been replaced, or when the batteries have been disconnected.
First, the test programs are executed by the robot computer (I/O computer) and the main computer. These tests and the test results are displayed on the teach pendant. If the tests do not indicate any errors, a message will appear on the display, requesting you to insert a system diskette into the disk drive. If, however, the diagnostics detect an error, a message will appear on the display and the test will be stopped until the user hits a key on the teach pendant or on a terminal connected to the front connector on the robot computer.
Warm Start is the normal type of start up when the robot is powered on. During a warm start, only a subset of the test program is executed. These tests and the test results are displayed on the teach pendant.
Another type of warm start, INIT, is carried out via a push button located on the backplane (see section 3). INIT is very similar to switching the power on. The tests that are run depend on whether or not the system is booted.
Product Manual 3
Troubleshooting Tools
Monitor Mode 2 is a test condition in which a large number of tests can be run. A detailed description will be found in Chapter 1.2.
Under normal operating conditions, a number of test programs are run in the background.
The operating system ensures that the tests can be run whenever there is a time slot.
The background tests are not seen in normal circumstances, but will give an indication when an error occurs.
Flow Chart of Diagnostic Software
= PROM memory code
Power on INIT
I/O
COMPUTER
RESET
Warm or cold start?
Warm
Cold
Cold start
Rudimentary
Run PROM tests
System boot
Set start up mode
Warm
Warm
Warm start
Rudimentary
Release system
Start up mode
Warm
4
System in operation
MAIN
COMPUTER
Set flag for warm start
Reset
Operating mode
Service mode
Product Manual
Troubleshooting Tools
1.1 Tests
Most of the internal robot tests are only run when the robot is cold started. All the tests can be run in Monitor Mode 2, as described in Chapter 1.2. Non destructive memory tests, checksum tests, etc., are only run when the robot is warm started.
Cold start tests in consecutive order.
IOC = Robot computer
AXC = Robot computer
MC = Main computer
At every “power on”, the IOC makes a destructive RWM test. If it fails, the IOC will flash the NS and MS front LEDs and stop the program running.
# T1504: IOC Red LED off
# T1005: IOC Memory test (RWM) Non Destructive
# T1018: IOC Battery test
# T1053: IOC IOC->AXC Access test
# T1062: IOC IOC->AXC AM test
# T1067: IOC IOC->AXC Memory test (RWM)
# T1068: IOC IOC->AXC Memory test (RWM) R6 Global
# T1069: IOC IOC->AXC Memory test (RWM) DSP
# T1070: IOC Enable AXC->IOC Interrupts
# T1061: IOC IOC->AXC Load AXC
# T3001: AXC RWM test Dist.
# T3002: AXC R6 Global RWM test
# T3003: AXC DSP Double access RWM test
# T3004: AXC DSP Data RWM test
# T3020: AXC VME interrupt test
# T3023: AXC Test channels output test
# T1071: IOC Disable AXC->IOC Interrupts
# T1046: IOC IOC->MC Access test
# T1048: IOC IOC->MC AM test
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Troubleshooting Tools
# T1050: IOC IOC->MC Memory test Destructive, Low win
# T1506: IOC IOC->MC LED off
# T1508: IOC IOC->ERWM LED off
# T1512: IOC IOC->MC Load MC
# T1509: IOC IOC->MC Release MC
# T2002: MC Memory test (RWM) Destructive
# T2010: MC Memory test (RWM) BM Destructive
# T1510: IOC IOC->MC Reset MC
Warm start tests in consecutive order.
IOC = Robot computer
At every “power on”, the IOC makes a destructive RWM test. If it fails, the IOC will flash the NS and MS front LEDs and stop the program running.
# T1504: IOC LED off
# T1005: IOC Memory test (RWM) Non Destructive
# T1018: IOC Battery test
1.2 Monitor Mode 2
When the system is in Monitor Mode 2, a large number of tests can be run.
These tests must be performed only by authorised service personnel. It should be noted that some of the tests will cause activity on customer connections and drive systems, which can result in damage, accidents etc. unless suitable precautionary measures are taken. It is advisable to disconnect all the connections involved during these tests.
To ensure that all memory addresses are resetted after testing shall the system be cold started.
The test mode Monitor mode 2 can be run from the teach pendant and/or a connected
PC/terminal.
6 Product Manual
Troubleshooting Tools
1.2.1 Entering the test mode from the teach pendant
1. Press the backplane TEST button, see section 3.
2. Keep the button depressed.
3. Push the INIT button, see section 3 (keep the TEST button pressed in).
4. Keep the TEST button depressed for at least 5 sec. (after releasing of the INIT button).
5. The display will show the following:
MONITOR MODE 2 if you proceed, system data will be lost! Press any key to accept.
6. Then enter the password: 4433221.
1.2.2 Console connected to a PC
A PC with terminal emulation (see PC manual). The PC shall be set up for 9600 baud, 8 bits, no parity, and shall be connected to the Console terminal on the front of the robot computer board.
Connection table: Console terminal on robot and main computer
Console
Pin
2
3
5
Signal
RXD
TXD
GND
Description
Serial receive data
Serial transmit data
Signal ground (0V)
Start up:
1. Connect the PC.
2. Turn on the power to the robot.
Entering the test mode from a PC/terminal:
1. Press the backplane TEST button, see section 3.
2. Keep the button depressed.
3. Push the INIT button, see section 3 (keep the TEST button pressed in).
4. Keep the TEST button depressed for at least 5 sec. (after release of the INIT button).
5. The display will show the following:
Product Manual 7
Troubleshooting Tools
MONITOR MODE 2 if you proceed, system data will be lost! Press any key on the PC to accept.
6. Then enter the password: ROBSERV.
When the password has been entered (see above), a menu will be displayed, as shown below:
Welcome to Monitor Mode 2
1. Memory IO
2. Serial IO
3. Elementary IO
4. DSQC 3xx (IOC)
5. DSQC 3xx (AXC)
6. DSQC 3xx (MC, ERWM)
7. System tests (MISC)
8. Auxiliary
9. Specific test
(Tests the memory)
(Tests the serial channels)
(Tests the IO units) Not yet implemented
(Tests the IO computer)
(Tests the axes computer)
(Tests the main computer and external memory boards)
(System-related tests)
(Special tests) Not yet implemented
(Specific tests that can be run separately)
10. T1060 IOC System reset
Select test group and the test group menu will be displayed.
1. T9901 Memory IO
1. Up one level
2. FLOPPY
1. Up one level
2. T1039 IOC Floppy Format Test
3. T1040 IOC Floppy Write/Read Test
3. IOC RWM
1. Up one level
2. T1516 TIOC RWM size
3. T1005 IOC Memory test (RWM) Non destructive
4. AXC RWM
1. Up one level
2. T1067 IOC->AXC Memory test (RWM)
3. T1068 IOC->AXC Memory test (RWM) R6 Global
4. T1069 IOC->AXC Memory test (RWM) DSP
5. T3001 AXC RWM test Destr
6. T3002 AXC R6 Global RWM test
7. T3003 AXC DSP Double access RWM test
8. T3004 AXC DSP Data RWM test
8 Product Manual
Troubleshooting Tools
5. MC/ERWM RWM
1. Up one level
2. T1517 MC/ERWM RWM size
3. T1047 IOC IOC->MC Memory test Destructive
4. T2002 MC Memory test (RWM) Destructive
5. T2010 MC Memory test (RWM) BM Destructive
6. PROM (Not yet implemented)
2. T9902 Serial I/O
1. Up one level
2. SIO 1 (Not yet implemented)
3. SIO 2
1. Up one level
2. T1029 IOC SIO2 RS422 loopback test
3. T1033 IOC SIO2 RS422 JUMPER test (Requires special hardware jumpers)
4. CONSOLE (Not yet implemented)
5. TPUNIT (Not yet implemented)
3. T9903 Elementary I/O (Not yet implemented)
4. T9911 DSQC 3xx (IOC)
1. Up one level
2. IOC CPU (Not yet implemented)
3. PROM (Not yet implemented)
4. RWM
1. Up one level
2. T1516 IOC RWM size
3. T1005 IOC Memory test (RWM) Non Destructive
5. RTC (Not yet implemented)
6. FDC
1. T9800 Up one level
2. T1039 IOC Floppy Format Test
3. T1040 IOC Floppy Write/Read Test
Product Manual 9
Troubleshooting Tools
7. UART
1. T9800 Up one level
2. T1029 IOC SIO2 RS422 loopback test
3. T1013 IOC TPUNIT RS422 loopback test
4. T1033 IOC SIO2 RS422 JUMPER test (requires special hardware jumpers)
5. T1022 IOC TPUNIT RS422 JUMPER test (Requires special hardware jumpers and must be run from terminal)
8. DMA (Not yet implemented)
9. VME (Not yet implemented)
10. Miscellaneous
1. Up one level
2. T1018 IOC Battery test startup
3. T1060 IOC System Reset
11. LED
1. Up one level
2. T1503 IOC LED on
3. T1504 IOC LED off
4. T1518 IOC CAN LEDs sequence test
5. DSQC 3xx (AXC)
1. Up one level
2. AXC CPU (Not yet implemented)
3. RWM
1. T9800 Up one level
2. T1067 IOC IOC->AXC Memory test (RWM)
3. T1068 IOC IOC->AXC Memory test (RWM) R6 Global
4. T1069 IOC IOC->AXC Memory test (RWM) DSP
5. T3001 AXC RWM test Dstr
6. T3002 AXC R6 Global RWM test
7. T3003 AXC DSP Double access RWM test
8. T3004 AXC DSP Data RWM test
4. VME
1. Up one level
2. T1053 IOC IOC->AXC Access test
3. T1062 IOC IOC->AXC AM test
4. T3020 AXC VME interrupt test
10 Product Manual
Troubleshooting Tools
5. Miscellaneous
1. Up one level
2. T1072 IOC IOC->AXC Reset AXC
3. T1071 IOC Enable AXC->IOC Interrupts
4. T1061 IOC IOC->AXC Load AXC
5. T3018 AXC ASIC ID number
6. T3019 AXC Board ID number
7. T3023 AXC Test channels output test
8. T1071 IOC Disable AXC->IOC Interrupts
6. DSQC 3xx (MC, ERWM)
1. Up one level
2. MC CPU (Not yet implemented)
3. RWM
1. Up one level
2. T1517 MC/ERWM RWM size
3. T1047 IOC IOC->MC Memory test Destructive
4. T2002 MC Memory test (RWM) Destructive
5. T2010 MC Memory test (RWM) BM Destructive
4. LED
1. Up one level
2. T1505 IOC IOC->MC LED on
3. T1506 IOC IOC->MC LED off
4. T1507 IOC IOC->ERWM LED on
5. T1508 IOC IOC->ERWM LED off
6. T2501 MC LED on
7. T2502 MC LED off
5. Duart (Not yet implemented)
6. VME
1. Up one level
2. T1048 IOC IOC->MC AM test
3. T1046 IOC IOC->MC Access test
7. DMA (Not yet implemented)
8. Miscellanous
1. Up one level
2. T1512 LOAD MC DIAG
3. T1509 ENABLE MC
4. T1510 DISABLE (RESET) MC
Product Manual 11
Troubleshooting Tools
7. System tests (Misc.)
1. Up one level
2. Battery
1. Up one level
2. T1018 IOC Battery test startup
3. IOC->MC
1. Up one level
2. T1046 IOC IOC->MC Access test
3. T1048 IOC IOC->MC AM test
4. T1505 IOC IOC->MC LED on
5. T1506 IOC IOC->MC LED off
6. T1507 IOC IOC->ERWM LED on
7. T1508 IOC IOC->ERWM LED off
8. T1512 LOAD MC DIAG
9. T1509 ENABLE MC
10. T1510 DISABLE (RESET) MC
11. T2501 MC LED on
12. T2502 MC LED off
4. IOC->AXC
1. T9800 Up one level
2. T1062 IOC IOC->AXC AM test
3. T1053 IOC IOC->AXC Access test
4. T1072 IOC IOC->AXC Reset AXC
5. T1070 IOC Enable AXC->IOC Interrupts
6. T1061 IOC IOC->AXC Load AXC
7. T3018 AXC ASIC ID number
8. T3019 AXC Board ID number
9. T3020 AXC VME interrupt test
10. T3023 AXC Test channels output test
11. T1071 IOC Disable AXC->IOC Interrupts
5. MC->AXC (Not yet implemented)
6. AXC->IOC (Not yet implemented)
7. VME (Not yet implemented)
8. RTC (Not yet implemented)
9. Reset password (Re-boot required)
10. Cold start (Not yet implemented)
8. Auxiliary (Not yet implemented)
12 Product Manual
Troubleshooting Tools
9. Specific test
Specific test Txxxx
<Q> <q> or < > to quit
Enter test number Txxxx: T
10. IOC System reset (Not yet implemented)
All available tests have been defined in Chapter 1.1.
Product Manual 13
Troubleshooting Tools
2 Indication LEDs on the Various Units
2.1 Location of units in the cabinet
Supply unit
Transformer
14
O
L
E
C
O
N
S
SIO1
TxD RxD
SIO2
TxD RxD
CAN
NS MS
DSQC
322
F
Drive unit
1
2
3
IRB 1400 IRB 2400 IRB 4400 IRB 6400 IRB 640
Axes Axes Axes Axes Axes
1, 2, 4
3, 5, 6
1, 2, 4
3, 5, 6
1, 6
2, 4
3, 5
1, 6
2, 4
3, 5
1, 6
2, 3
IRB 840/A
Axes
1(X), 6(C)
2(Y), 3(Z)
2.2 Robot computer DSQC 363/373
Designation Colour
F Red
TxD
RxD
NS
MS
Yellow
Yellow
Green/red
Green/red
Description/Remedy
Turns off when the board approves the initialisation.
Product Manual
DSQC
361
F
Troubleshooting Tools
2.3 Main computer DSQC 361
Designation
F
Colour
Red
Description/Remedy
Turns off when the board approves the initialisation.
DSQC
3xx
F
F
2.4 Memory board DSQC 324/16Mb, 323/8Mb
Designation Colour Description/Remedy
Red Turns off when the board approves the initialisation.
Product Manual 15
Troubleshooting Tools
LAN
TXD RXD
CAN
NS MS
A
I
U
NS
MS
F
2.5 Ethernet DSQC 336
Designation
TxD
RxD
Colour
Yellow
Yellow
Green/red
Green/red
Red
Description/Remedy
Indicates data transmit activity.
If no light when transmission is expected, check error messages and check also system boards in rack.
Indicates data receive activity.
If no light, check network and connections.
Lit after reset. Thereafter controlled by the CPU.
Light without message on display indicates a hardware fault preventing system from strating.
By light and message on display, check message.
C
O
N
S
O
L
E
F
T
P
E
DSQC
336
16 Product Manual
Troubleshooting Tools
DSQC 334
2.6 Power supply units
X1
X2
AC OK
X5
X3
Designation
AC OK
Colour
Green
Description/Remedy
3 x 55V supply OK
(start of ENABLE chain)
DSQC 374/365
New “standard” power supply unit DSQC 374, introduced week 826 (M98 rev. 1)
New “extended” power supply unit DSQC 365 introduced week 840.
Product Manual 17
Troubleshooting Tools
X1
X5
X3
AC OK
X2
24 V I/O
X7
Designation Colour
AC OK Green
24 V I/O Green
Description/Remedy
3 x 55V supply OK
(start of ENABLE chain)
24 V I/O OK
Only
DSQC 365
18 Product Manual
Troubleshooting Tools
2.7 Panel unit DSQC 331
Status LED’s
WARNING!
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN MS NS ES1 ES2 GS1 GS2 AS1 AS2
Designation
EN
MS/NS
ES1 and 2
GS1 and 2
AS1 and 2
Colour
Green
Green/red
Yellow
Yellow
Yellow
Description/Remedy
Enable signal from power supply and computers
Emergency stop chain 1 and 2 closed
General stop switch chain 1 and 2 closed
Auto stop switch chain 1 and 2 closed
Product Manual 19
Troubleshooting Tools
2.8 Digital and Combi I/O units
All the I/O units have the same LED indications. The figure below shows a digital
I/O unit, DSQC 328.
The description below is applicable for the following I/O units:
Digital I/O DSQC 328, Combi I/O DSQC 327,
Relay I/O DSQC 332 and 120 VAC I/O DSQC 320.
Status LED’s
1 2 3 4 5 6 7 8
OUT
IN
X1
X3
1 10
X2
X4
1
MS
NS
9 10 11 12 13 14 15 16
10
1 10
1 10
OUT
IN
12 1
X5
Designation
IN
OUT
MS/NS
Colour
Yellow
Yellow
Green/red
Description/Remedy
Lights at high signal on an input.
The higher the applied voltage, the brighter the LED will shine. This means that even if the input voltage is just under the voltage level “1”, the LED will glow dimly.
Lights at high signal on an output.
The higher the applied voltage, the brighter the LED will shine.
20 Product Manual
Troubleshooting Tools
2.9 Analog I/O, DSQC 355
Bus staus LED’s
X8
S2 S3
X2
X5 X3
X7
Analog I/O
DSQC 355
ABB flexible Automation
N.U
RS232 Rx
CAN Rx
+5V
+12V
MS
Bus status LED’s
N.U
RS232 Tx
CAN Tx
-12V
NS
Designation
NS/MS
RS232 Rx
Colour
Green/red
Green
RS232 Tx
+5VDC / +12VDC /
-12VDC
Green
Green
Description/Remedy
Indicates the state of the RS232 Rx line.
LED is active when receiving data.
If no light, check communication line and connections.
Indicates the state of the RS232 Tx line.
LED is active when tranceiving data.
If no light when transmission is expected, check error messages and check also system boards in rack.
Indicates that supply voltage is present and at correct level.
Check that voltage is present on power unit.
Check that power is present in power connector.
If not, check cables and connectors.
If power is applied to unit but unit does not work, replace the unit.
Product Manual 21
Troubleshooting Tools
2.10 Remote I/O DSQC 350, Allen Bradley
X5
X9
X3
DSQC 350
X8
ABB Flexible Atomation
Bus status LED’s
POWER
NS
MS
CAN Tx
CAN Rx
NAC STATUS
Designation
POWER-24 VDC
Colour
Green
NS/MS Green/red
CAN Tx/CAN Rx Yellow
NAC STATUS Green
Description/Remedy
Indicates that a supply voltage is present, and has a level above 12 VDC.
If no light, check that voltage is present on power unit. That power is present in power connector. If not, check cables and connectors.
If power is applied to unit but unit does not work, replace unit.
Steady green indicates RIO link in operation.
If no light, check network, cables and connections.
Check that PLC is operational.
Flashing green, communication established, but INIT_COMPLETE bit not set in NA chip, or configuration or rack size etc. not matching configuration set in PLC.
If LED keeps flashing continuously, check setup
22 Product Manual
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Troubleshooting Tools
2.11 Interbus-S, slave DSQC 351
RC
BA
RBDA
POWER
CAN Rx
CAN Tx
MS
NS
POWER
X20
X21
X5 X3
Bus status LED’s
POWER
NS
MS
CAN Tx
CAN Rx
POWER
RBDA
BA
RC
Designation
POWER-24 VDC
NS/MS
CAN Tx/CAN Rx
POWER- 5 VDC
RBDA
BA
RC
Colour Description/Remedy
Green Indicates that a supply voltage is present, and has a level above 12 VDC.
Green Lit when both 5 VDC supplies are within limits, and no reset is active.
Red
Green
Green
Lit when this Interbus-S station is last in the Interbus-S network.
If not as required, check parameter setup.
Lit when Interbus-S is active.
If no light, check network, nodes and connections
Lit when Interbus-S communication runs without errors.
23
Troubleshooting Tools
2.12 Profibus-DP, DSQC352
X20
PROFIBUS ACTIVE
NS
MS
CAN Tx
CAN Rx
POWER
X5 X3
Bus status LED’s
Profibus active
NS
MS
CAN Tx
CAN Rx
Power
Designation
Profibus active with
NS/MS
CAN Tx/CAN Rx
POWER, 24 VDC
Colour Description/Remedy
Green Lit when the node is communicating the master. If no light, check system messages in robot and in Profibus net.
Green Indicates that a supply voltage is present, and has a level above 12 VDC.
If no light, check that voltage is present in power unit.Check that power is present in the power connector. If not, check cables and connectors. If power is available at the unit but the unit does not function, replace the unit
24 Product Manual
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Troubleshooting Tools
2.13 Encoder interface unit, DSQC354
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
CAN Rx
CAN Tx
MS
NS
POWER
X20
X5 X3
Status LED’s
POWER
NS
MS
CAN Tx
CAN Rx
ENC 1A
ENC 1B
DIGIN 1
Designation
POWER, 24 VDC
NS/MS
CAN Tx/CAN Rx
ENC 1A/1B
Colour Description/Remedy
Green Indicates that a supply voltage is present, and has a level above 12 VDC.
If no light, check that voltage is present on power unit. That power is present in connector X20. If not, check cables and connectors.If power is applied to unit but unit does not work, replace unit.
Green/red
Yellow
Green
Indicates phase 1 and 2 from encoder.
Flashes by each Encoder pulse.
By frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker).
If no light, faulty power supply for input circuit (internal or external). Defective input circuit on board. External wiring or connectors, short circuit or broken wire.
Internal error in unit. Constant light indi cates constant high level on input and vice versa. No light in one LED indicates fault in one encoder phase.
25
Troubleshooting Tools
DIGIN1 Green Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point.
If no light, faulty limit switch, photocell etc. External wiring or connectors, short circuit or broken wire. Faulty power supply for input circuit (internal or external).
Defective input circuit on board.
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2.14 Status LEDs description
Each of the units connected to the CAN bus includes 2 or 4 LED indicators which indicate the condition (health) of the unit and the function of the network communication. These
LEDs are:
All units
Some units:
MS - Module status
This bicolour (green/red) LED provides device status. It indicates whether or not the device has power and is operating properly. The LED is controlled by software. The table below shows the different states of the MS LED.
Description
Off
No power applied to the device.
Green
Device is operating in a normal condition.
Flashing green
Device needs commissioning due to configuration missing, incomplete or incorrect. The device may be in the
Stand-by state.
Flashing red
Recoverable minor fault.
Red
The device has an unrecoverable fault.
Flashing red/green
The device is running self test.
Remedy / Source of fault
Check power supply.
If no light, check other LED modes.
Check system parameters.
Check messages.
Check messages.
Device may need replacing.
If flashing for more than a few seconds, check hardware.
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Troubleshooting Tools
NS - Network status
The bicolour (green/red) LED indicates the status of the communication link. The LED is controlled by software. The table below shows the different states of the NS LED.
Description
Off
Device has no power or is not on-line.
The device has not completed the
Dup_MAC_ID test yet.
Flashing green
Device is on-line, but has no connections in the established state.
The device has passed the Dup_MAC_ID test, is on-line, but has no established connections to other nodes.
For a group 2 only device it means that the device is not allocated to a master.
For a UCMM capable device it means that the device has no established connections.
Green
The device is on-line and has connection in the established state.
For a group 2 only device it means that the device is allocated to a master.
For a UCMM capable device it means that the device has one or more established connections.
Flashing red
One or more I/O connections are in the
Time-Out state.
Red
Failed communication device. The device has detected an error that has rendered it incapable of communicating on the network.
(Duplicate MAC_ID, or Bus-off).
Remedy / Source of fault
Check status of MS LED.
Check power to affected module.
Check that other nodes in network are operative.
Check parameter to see if module has correct ID.
If no light, check other LED modes.
Check system messages.
Check system messages and parameters.
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Module- and network status LEDs at power-up
The system performs a test of the MS and NS LEDs during start-up. The purpose of this test is to check that all LEDs are functioning properly. The test runs as follows:
- - NS LED is switched Off.
- - MS LED is switched On green for approx. 0.25 seconds.
- - MS LED is switched On red for approx. 0.25 seconds.
- - MS LED is switched On green.
- - NS LED is switched On green for approx. 0.25 seconds.
- - NS LED is switched On red for approx. 0.25 seconds.
- - NS LED is switched On red.
If a device has other LEDs, each LED is tested in sequence.
CAN Tx - CAN network transmit
Description
Green LED. Physically connected to the
Can Tx line. Flashes when the CPU is receiving data on the CAN bus.
Remedy / Source of fault
If no light when transmission is expected, check error messages.
Check system boards in rack.
CAN Rx - CAN network receive
Description
Green LED. Physically connected to the
Can Rx line. Flashes when the CPU is transmitting data on the Can bus.
Remedy / Source of fault
If no light, check network and connections.
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Troubleshooting Tools
3 Measuring Points
3.1 Back plane
The backplane contains a maintenance plug (X9) for signals that are hard to reach. Other signals are measured at their respective connection points, which can come in very handy when
troubleshooting (see Figure 1).
SIO1 and SIO 2 can also be D-sub contacts, both variants will exist.
alt.
Test points X5-X8
Serial ports
SIO 1 RS 232
SIO2 RS 422
Battery 1 2
Maintenance plug, X9
CAN3 (ext. I/O)
CAN2 (manip. I/O)
CAN1 (panel unit)
Disk drive
- data
- supply
Drive units,
X14 (ext. axes)
Serial meas.
board 2, X12
(ext. axes)
Accessible from cabinet top
Accessible by cabinet door
S1 = INIT button
S2 = TEST button
Drive units,
X22
(manipulator)
Serial meas. board 1, X23
(manipulator)
Power contact can also be a 15-pole contact, both variant will exsist
30
Power supply
Figure 1 Back plane
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Troubleshooting Tools
3.2 Signal description, RS 232 and RS 422
RS 232
Signal Explanation
TXD Transmit Data
RXD Receive Data
DSR Data Set Ready
DTR Data Terminal Ready
CTS Clear To Send
RTS Request To Send
Stop bit (“1”)
Start bit (“0”)
10 V
0 V
Byte 1 Byte 2 f=9600/19200 baud
Figure 2 Signal description for RS 232.
The transmission pattern can be single or bursts of 10 bit words, with one start bit “0”, eight data bits (MSB first) and lastly one stop bit “1”.
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Troubleshooting Tools
RS 422
Signal Explanation
TXD4/TXD4 N Transmit Data in Full Duplex Mode
RXD4/RXD4 N Receive Data in Full Duplex Mode
DATA4/DATA4 N Data Signals in Half Duplex Mode
DCLK4/DCLK4 N Data Transmission Clock
N.B! Only full duplex is supported.
Signal XXX
5 V
5 V
Signal XXX N f= 9600 38400 baud
Figure 3 Signal description for RS 422, differential transmission.
When measuring the differential RS 422 signals, the oscilloscope should be set for AC testing. The data transmission has the same structure as RS 232, i.e. 1 start bit + 8 data bits + 1 stop bit, but the signals are differential. By looking at the “true” channel, it is possible to read the data.
If the types of signal as shown in the above diagram are obtained when measuring, this means that the drive circuits and lines are OK. If one or both of the signals do not move, it is likely that one or several line(s) or one or several drive circuit(s) is/are faulty.
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3.3 X1 and X2 Serial links: SIO 1 and SIO 2
General serial interfaces: SIO 1 (X1) is an RS232 interface and
SIO 2 (X2) is an RS422 interface. Explanation of signals see 3.2.
Screw terminals
9
10
7
8
11
12
5
6
3
4
X1
Pin
1
2
Signal
TXD
RTS N
0V
RXD
CTS N
0V
DTR
DSR
0V 9
10
7
8
11
12
5
6
3
4
X2
Pin
1
2
Signal
TXD
TXD N
0V
RXD
RXD N
0V
DATA
DATA N
0V
DCLK
DCLK N
0V
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Troubleshooting Tools
D-sub connector
5
6
3
4
X1
Pin
1
2
7
8
9
Signal
RXD
TXD
DTR
0 V
DSR
RTS N
CTS N
5
6
3
4
X2
Pin
1
2
7
8
9
Signal
TXD
TXD N
RXD
RXD N
0 V
DATA
DATA N
DCLK
DCLK N
3.4 X9 Maintenance plug
3.4.1 Power supply
Supply voltages can be measured at the following points:
30
31
32
X9
Pin
28
29
Row A
ACOK
+ 5V_TST
+ 15V_TST
15V_TST
+ 24V_TST
Row C
DCOK
0V
0V
0V
0V
There is a 10 k
Ω
resistor between each power supply line and the test terminal to prevent damage by a short circuit.
ACOK: Follows the AC power input without delay. High (= 5V) when power is OK.
DCOK: Follows the supply unit energy buffer. After power on, DCOK goes high (=5
V) when output voltages are stable.
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3.4.2 X9 VBATT 1 and 2
Battery back-up for the computer memory and the real time clock.
Voltage of batteries 1 and 2; the voltage must be between 3.3 V and 3.9 V.
X9
Pin
7
8
Row A
VBATT1
0V
Row C
VBATT2
0V
3.4.3 Drive system
The signal interface with the drive system. It complies with the EIA RS 422 standard,
which means that signal transmission is differential. See 3.2 (Figure 3).
18
19
20
X9
Pin
16
17
A
DRCI1
DRCO1
DRCI2
DRCO2
0V
C
DRCI1 N
DRCO1 N
DRCI2 N
DRCO2 N
The DRCO signals travel from the robot computer to the drive units.
The DRCI signals enter the robot computer from the drive units.
DRCI1/DRCO1 signals are connected to the internal drive system (backplane connec-
DRCI2/DRCO2 are connected to external placed drive units (backplane connector
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Troubleshooting Tools
3.4.4 Measuring system
The signal interface with the serial measuring system. It complies with the EIA RS 422
standard, which means that signal transmission is differential, see 3.2 (Figure 3).
22
23
24
X9
Pin
20
21
A
MRCI1
MRCO1
MRCI2
MRCO2
C
0V
MRCI1 N
MRCO1 N
MRCI2 N
MRCO2 N
The MRCO signals travel from the robot computer to the measuring boards.
The MRCI signals enter the robot computer from the measuring boards.
MRCI1/MRCO1 signals are connected to the IRB axes (backplane connector X23,
MRCI2/MRCO2 are used for external axes (backplane connector X12, see 3.1).
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3.4.5 Disk drive
The signal interface with the disk drive; TTL levels “0” <=> 0V, “1” <=> +5V.
X9
Pin
9
A
RD N
10
12
WP N Write Protect, static active low. Indicates whether or not the diskette is write protected.
11 DSKCHG N Disk Change, static active low. Indicates whether or not there is a diskette in the unit.
WD N Write Data, pulses. Data pulses when writing to the diskette.
13 SSO N
Explanation
Read Data, pulses. Data pulses when reading the diskette
14 DIRC N
Side Select, static active low. Indicates which side of the diskette is active.
Direction in, static active low. Indicates that the heads are to move inwards.
15 0V
X9
Pin
9
10
11
12
13
14
15
C
IP N
TR00 N
MO N
WG N
STEP N
HD N
0V
Explanation
Index, pulses. One pulse per cycle, c. every 200 milliseconds.
Track 00, active low. Indicates that the heads are located at track 0 of the diskette.
Motor on, static low. Starts the motor in the selected unit.
Write Gate, pulses. Enables writing.
Step, pulses. Steps the heads in the direction indicated by DIRC N.
High Density, static active low. Indicates that a 1.44
MB diskette is in the unit.
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Troubleshooting Tools
MOTOR ON
DRIVE SELECT
STEP
WRITE GATE
WRITE DATA
Write frequency
MOTOR ON
DRIVE SELECT
STEP
WRITE GATE
READ DATA
Read frequency
Figure 4 Diagram of write and read frequencies.
3.4.6 Teach pendant
The data transmission signal complies with the EIA RS 422 standard, see 3.2
X9
Pin
6
A
DATA4=TP
C
DATA4-N=TP-N
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3.4.7 CAN
X9
Pin A
25 CANRLY2 N
26 CAN_H
C
CANRLY3 N
CAN_L
CANRLY2 N and CANRLY3 N respectively:
0V when CAN 2 or CAN 3 is active (see Installation and Commissioning, section
3.17.3).
24V when CAN 2 and CAN 3 are disconnected (see Installation and Commissioning, section 3.17.3). In this case the backplane fixed termination resistor is connected in.
3.4.8 Safety
X9
Pin
27
A
ENABLE9
C
SPEED
ENABLE 9:
5V when supply voltage is OK and the computers are OK (output from the robot computer to the panel unit; LED EN).
SPEED:
5V when one of the modes AUTO or MANUAL FULL SPEED is active (input to the robot computer from the panel unit).
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Troubleshooting Tools
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Fault tracing guide
CONTENTS
Page
1.3 Main computer DSQC 361 and memory board DSQC 323/324 ...................... 4
1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant 6
Product Manual 1
Fault tracing guide
2 Product Manual
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1 Fault tracing guide
Sometimes errors occur which neither refer to an error message nor can be remedied with the help of an error message.
To make a correct error diagnosis of these particular cases, you must be very experienced and have an in-depth knowledge of the control system. This section of the Product Manual is intended to provide support and guidance in any diagnostic work.
1.1 Starting Troubleshooting Work
Always start off by consulting a qualified operator and/or check any log books available to get some idea of what has happened, to note which error messages are displayed, which LEDs are lit, etc. If possible, look at the control system’s error log; if there are any error messages there, it can be accessed from the Service menu. On the basis of this error information, you can start your analysis using the various tools, test programs, measuring points, etc., available.
Never start off by wildly replacing boards or units since this can result in new errors being introduced into the system.
When handling units and other electronic equipment in the controller, the wrist strap in the controller must be used to avoid ESD damage.
1.1.1 Intermittent errors
Unfortunately, intermittent errors sometimes occur and these can be difficult to remedy. This problem can occur anywhere in the robot and may be due to external interference, internal interference, loose connections, dry joints, heating problems, etc.
To identify the unit in which there is a fault, note and/or ask a qualified operator to note the status of all the LEDs, the messages on the teach pendant, the robot’s behaviour, etc., each time that type of error occurs.
It may be necessary to run quite a number of test programs in order to pinpoint the error; these are run in loops, which should make the error occur more frequently.
If an intermittent error occurs periodically, check whether something in the environment in which the robot is working also changes periodically. For example, it may be caused by electrical interference from a large electric plant which only operates periodically. Intermittent errors can also be caused by considerable temperature changes in the workshop, which occur for different reasons.
Disturbances in the robot environment can affect cabling, if the cable screen connections are not intact or have been incorrectly connected.
1.1.2 Tools
Usually, the following tools are required when troubleshooting:
- Normal shop tools
- Multimeter
- Oscilloscope
- Recorder
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Fault tracing guide
1.2 Robot system
In this instance the robot system means the entire robot (controller + manipulator) and process equipment.
Errors can occur in the form of several different errors where it is difficult to localise one particular error, i.e. where it is not possible to directly pinpoint the unit that caused the problem. For example, if the system cannot be cold-started, this may be due to several different errors (the wrong diskette, a computer fault, etc.).
1.3 Main computer DSQC 361 and memory board DSQC 323/324
The main computer, which is connected to the VME bus and the local bus of the memory board, looks after the higher-level administrative work in the control system. Under normal operating conditions, all diagnostic monitoring is controlled by the main computer. At start-up, irrespective of whether a cold or warm start is performed, the robot computer releases the main computer when the robot computer’s diagnostics allows it and, following this, the main computer takes over the control of the system. The read and write memories of the main computer are battery-backed.
If the red LEDs on the main computer light up (or do not turn off at initialisation), either a critical system failure has occurred or the main computer board or memory board is faulty.
The memory board is an extension of the main computer memory.
The memory board has a LED, F, which is lit and turned off by the main computer.
If there is a memory error on one of these boards, an error code will be shown on the display, T1047 or T2010. These error codes also include a field called the At address, which in turn contains an hexadecimal code that indicates on which board the erroneous memory circuit is located.
When the error is in the main computer, the hexadecimal code is in the following range:
0 X 000000 - 0 X 7FFFFF
When the error is in the memory board, the code is above 0 X 800 000.
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Fault tracing guide
1.4 Robot computer DSQC 363
The robot computer, which controls the system’s I/O, axis control, serial communication and teach pendant communication, is the first unit to start after a cold or warm start. The red LED on the front of the board goes off immediately when the system is reset and goes on again if an error is detected in the tests. As mentioned above, the robot computer releases the main computer when the preliminary diagnostics have given the go ahead-signal.
The read and write memories of the robot computer are battery-backed.
If the system does not start at all, and the LED on the robot computer goes on, the error is probably in the robot computer.
1.5 Panel unit DSQC 331
The DSQC 331 Panel unit controls and monitors the dual operation chain. Its status is also indicated by LEDs at the upper part of the unit.
Over temperature of the motors is monitored by PTC inputs to the board.
LED indications for DSQC 331
Marking
EN
MS
NS
ES 1 and 2
GS 1 and 2
AS 1 and 2
Colour
Green
Green/red
Green/red
Yellow
Yellow
Yellow
Meaning
Indicates “go ahead” from the control system
Module status, normally green, see also section 1.6
Network status, normally green, see also section 1.6
EMERGENCY STOP, chain 1 and 2 closed
GENERAL STOP switch, chain 1 and 2 closed
AUTO STOP switch, chain 1 and 2 closed
The LEDs are very useful when trying to locate errors in the operation chain. Unlit
LEDs indicate the whereabouts of an error in the operation chain, making the error easy to locate in the system circuit diagram.
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Fault tracing guide
1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant
• Select the I/O window.
• Call up the Units list by choosing View.
• Select the Safety unit.
The location of the status signals are found in the circuit diagram, regarding Panel unit, where outputs are marked with and inputs with
See the table below.
Outputs DO
Name
BRAKE
Meaning when “1” is displayed
Energise brake contactor (i.e. release brakes) and turn on duty time counter
MONLMP Turn on LED in motor-on push button
RUN CH1 Energise motor contactor chain 1
RUN CH2 Energise motor contactor chain 2
SOFT ASO Choose delayed turn off of auto stop
SOFT ESO Choose delayed turn off of emergency stop
SOFT GSO Choose delayed turn off of general stop
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Fault tracing guide
Inputs DI
K1
K2
LIM1
LIM2
MAN2
MANFS2
MANORFS1
MON PB
PTC
PTC Ext.
SOFT ASI
SOFT ESI
SOFT GSI
TRFOTMP
24V panel
Name
AS1
AS2
AUTO1
AUTO2
CH1
CH2
EN1
EN2
ES1
ES2
ENABLE
EXTCONT
FAN OK
GS1
GS2
Product Manual
Meaning when “1” is displayed
Auto stop chain 1 closed
Auto stop chain 2 closed
Mode selector chain 1; Auto operation
Mode selector chain 2; Auto operation
All switches in chain 1 closed
All switches in chain 2 closed
Enabling device chain 1 closed
Enabling device chain 2 closed
Emergency stop chain 1 closed
Emergency stop chain 2 closed
Enable from backplane
External contactors closed
Fan in power supply running
General stop chain 1 closed
General stop chain 2 closed
Motor contactor, chain 1, closed
Motor contactor, chain 2, closed
Limit switch chain 1 closed
Limit switch chain 2 closed
Mode selector chain 2; Manual operation
Mode selector chain 2; Manual full speed operation
Mode selector chain 1; Manual or manual full speed operation
Motor-On push button pressed
Over temperature in motors of manipulator
Over temperature in external device
Delayed turn off of auto stop (read back of digital output)
Delayed turn off of emergency stop (read back of digital output)
Delayed turn off of general stop (read back of digital output)
Over temperature in main transformer
24V panel is higher than 22V
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Fault tracing guide
1.6 Distributed I/O
I/O units communicate with the I/O computer, located on the robot computer board, via the CAN bus. To activate the I/O units they must be defined in the system parameters.
The I/O channels can be read and activated from the I/O menu on the teach pendant.
In the event of an error in the I/O communication to and from the robot, check as follows:
1. Is I/O communication programmed in the current program?
2. On the unit in question, the MS (Module status) and NS (Network status) LEDs must be lit with a fixed green colour. See the table below regarding other conditions:
MS LED is:
Off
Green
Flashing green
Flashing red/green
Flashing red
Red
To indicate
No power
Normal condition
Software configuration missing, standby state
Device self testing
Minor fault (recoverable)
Unrecoverable fault
Action
Check 24 V CAN
Configure device
Wait for test to be completed
Restart device
Replace device
8
NS LED is:
Off
Flashing green
Green
Red
To indicate
Not powered/not on-line
On-line, not connected
On-line, connections established
Critical link failure, incapable of communicating (duplicate MAC ID, or bus-off)
Action
Wait for connection
Change MAC ID and/ or check CAN connection/cables
3. Check that the current I/O signal has the desired status using the I/O menu on the tech pendant display.
4. Check the I/O unit’s LED for the current input or output. If the output LED is not lit, check that the 24 V I/O power supply is OK.
5. Check on all connectors and cabling from the I/O unit to the process connection.
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Fault tracing guide
1.7 Serial Communication
The most common causes of errors in serial communication are faulty cables (e.g. mixed-up send and receive signals) and transfer rates (baud rates), or data widths that are incorrectly set. If there is a problem, check the cables and the connected equipment before doing anything else.
The communication can be tested using the integral test-program, after strapping the input to the output. See chapter 9.
1.8 Drive System and Motors
The drive system, which consists of rectifier, drive unit and motor, is controlled by the axis computer, located on the robot computer board.
DC link
Computer
Rotor position Torque reference
Drive Unit M
Serial measurement board
R
Figure 1 A schematic description of the drive system.
The drive system is equipped with internal error supervision. An error is sent on via the robot computer and can be read on the teach pendant display as an error message. An explanation of the available error messages can be found in the User’s Guide, System and error messages, section 3, error no. 39XXX.
If a drive unit or rectifier is faulty, the unit should be replaced. Internal troubleshooting cannot be performed in the operating environment.
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Fault tracing guide
1.9 Teach Pendant
The teach pendant communicates with the robot computer via a cable. This cable is also used for the +24 V supply and the dual operation chain.
If the display is not illuminated, try first adjusting the contrast, and if this does not help check the 24 V power supply.
Communication errors between the teach pendant and the I/O computer are indicated by an error message on the teach pendant.
For measuring points for the teach pendant communication signals, see chapter 9.
1.10 Measurement System
The measurement system comprises an axis computer, one or more serial measurement boards and resolvers. The serial measurement board is used to collect resolver data. The board is supplied from 24 V SYS via a fuse on the back plane. The board is located in the manipulator and is battery-backed. Communication with the axis computer takes place across a differential serial link (RS 485).
The measurement system contains information on the position of the axes and this information is continuously updated during operation. If the resolver connections are disconnected or if the battery goes dead after the robot has been stationary for a long period of time, the manipulator’s axis positions will not be stored and must be updated.
The axis positions are updated by manually jogging the manipulator to the synchronised position and then, using the teach pendant, setting the counters to zero. If you try to start program execution without doing the above, the system will give an alarm to indicate that the system is not calibrated.
Measuring points for the measurement system are located on the backplane, X9 Maintenance plug, see chapter 9 for more detailed information.
Note that it is necessary to re-calibrate after the resolver lines have been disconnected. This applies even if the manipulator axes have not been moved.
Transmission errors are detected by the system’s error control, which alerts and stops program execution if necessary.
Common causes of errors in the measurement system are line breakdown, resolver errors and measurement board interference. The latter type of error relates to the 7th axis, which has its own measurement board. If it is positioned too close to a source of interference, there is a risk of an error.
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1.11 Disk Drive
The disk drive is controlled by the I/O computer via a flat cable. The power is supplied by a separate cable.
Common types of error are read and write errors, generally caused by faulty diskettes. In the event of a read and/or write error, format a new, high quality diskette in the robot and check to see whether the error disappears. If the error is still present, the disk drive will probably have to be replaced. However, check the flat cable first.
NB: Never use diskettes without a manufacturer’s mark. Unmarked, cheap diskettes can be of very poor quality.
If the disk drive is completely dead, check the supply voltage connection to the disk drive to see that it is +5 V, before replacing the drive.
Measuring points are available on the backplane: X9 Maintenance plug, see chapter 9.
When replacing the disk drive, check that the strapping is set correctly on the unit. Compare with the faulty drive being replaced.
1.12 Fuses
There is one automatic three-phase 20 A fuse that supplies the DC-link in the MOTORS
ON state, on the transformer. There is also a automatic three-phase 10 A fuse that supplies the power supply unit. There are also two fuses for customer AC supplies, one 3.15 A and one 6.3 A.
The backplane has four PTC resistance fuses:
- Serial measurement board 1
- Serial measurement board 2
- CAN2, manipulator I/O
- CAN3, external I/O
The fuses protect against 24 V short-circuits and return to the normal state when there is no longer a risk of short-circuiting.
The panel unit has one PTC fuse to protect the motor on chains. An open fuse is indicated
on the teach pendant, see Status of the Panel unit, inputs and outputs, displayed on the teach
The cabling from customer 24 V supply is protected by a 2A fuse on terminal XT31 in the upper compartment of the controller.
Note that the power supply unit DSQC 374 is provided with a short circuit energy limitation which makes the fuse unnecessary.
Product Manual 11
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12 Product Manual
ABB Flexible Automation AB
T
his chapter is not included in the On-line Manual
.
Click on the Main menu button below to continue to the front page.
Main menu
Repairs
CONTENTS
Page
1.5.1 Screws with slotted or cross recessed head.................................................. 9
6.1.2 Changing the intermediate gear including sealing....................................... 30
Product Manual IRB 2400 1
Repairs
CONTENTS
Page
6.2.2 Changing the drive shaft unit, gear belts or motors ..................................... 34
6.2.3 Changing the motor or driving belt of axes 5 and 6 .................................... 36
10.6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16)........................... 46
10.7 Changing and checking the oil in gearbox 4 (IRB 2400L) .................................. 47
10.8 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400/10/16) ............. 47
10.9 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400L) ..................... 48
11.2 Adjustment procedure using calibration equipment (fine calibration)................. 49
2 Product Manual IRB 2400
Repairs General Description
1 General Description
The IRB 2400 industrial robot system comprises two separate units: the control cabinet and the manipulator. Servicing the mechanical unit is described in the subsequent chapters.
When servicing the manipulator, it is helpful to service the following parts separately:
• The Electrical System
• The Motor Units
• The Mechanical System
The Electrical System is routed through the entire manipulator and is made up of two main cabling systems: the power cabling and signal cabling. The power cabling feeds the motor units of the manipulator axes. The signal cabling feeds the various control parameters, such as axis positions, motor revs, etc.
The AC Motor Units provide the motive power for the various manipulator axes, driving them through gearboxes. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 3 minutes during both automatic operation and manual operation.
The Mechanical System has 6 axes which make its movements very flexible.
Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion.
The lower arm, together with the radius rod and the parallel bracket, form a parallelogram relative to the upper arm. The parallel bracket is mounted on bearings in the radius rod and in the upper arm.
Axis 3 raises the upper arm of the manipulator. Axis 4, located on the upper arm, rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes
5 and 6. These axes form a cross.
Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically controlled by means of an external air supply (optional extra). The signals to/ from the tool can be supplied via internal customer connections (optional extras).
Note that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards, cabling, resolver unit).
When any type of maintenance work is carried out, the calibration position of the manipulator must be checked before the robot is returned to the operational mode.
Take special care when manually operating the brakes. Make sure also that the safety instructions in this manual are followed when starting to operate the robot.
Product Manual IRB 2400 3
General Description Repairs
1.1 Instructions for reading the following chapters
The subsequent chapters describe the type of on-site maintenance that can be performed by the customer’s own maintenance staff. Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB Flexible Automation for service.
Calibration: The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the motor and feedback unit is disconnected, when a resolver error occurs, or when the power supply between a measurement board and resolver is inter-
rupted. This procedure is described in detail in chapter 11, Calibration.
Any work on the robot signal cabling may cause the robot to move to the wrong positions.
After performing such work, the calibration position of the robot must be checked
as described in chapter 11, Calibration.
Tools: Two types of tools are required for the various maintenance jobs. It may be necessary to use conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on the type of servicing. Conventional tools are not discussed in this manual, since it is assumed that maintenance staff have sufficient basic technical competence. Maintenance jobs which require the use of special tools are, on the other hand, described in this manual.
Foldouts: The chapter on spare parts comes with a number of foldouts which illustrate the parts of the robot. These foldouts are provided in order to make it easier for you to quickly identify both the type of service required and the make-up of the various parts and components. The item numbers of the parts are also shown on the foldouts.
In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference is made to a foldout, other than that specified in the paragraph title, the foldout’s number is included in the numeric reference to its item number; for example:
<5/19> or <10:2/5>. The digit(s) before the stroke refer to the foldout number.
The foldouts also include other information such as the article number, designation and related data.
NB: This manual is not construed as a substitute for a proper training course. The information in the following chapters should be used only after an appropriate course has been completed.
4 Product Manual IRB 2400
Repairs General Description
1.2 Caution
The mechanical unit contains several parts which are too heavy to lift manually.
As these parts must be moved with precision during any maintenance and repair work, it is important that suitable lifting equipment is available.
The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.
1.3 Fitting new bearings and seals
1.3.1 Bearings
1.
Do not unwrap new bearings until just before assembly, in order to prevent dust and grit getting into the bearing.
2.
Make sure that all parts of the bearing are free from burr dust, grinding dust and any other contamination. Cast parts must be free from foundry sand.
3.
Bearing rings, races and roller parts must not under any circumstances be subjected to direct impact. The roller parts must not be subjected to any pressure that is created during the assembly.
Tapered bearings
4.
The bearing should be tightened gradually until the recommended pre-tensioning is attained.
5.
The roller parts must be rotated a specified number of turns both before pretensioning and during pre-tensioning.
6.
The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange.
7.
It is important to position the bearings correctly, because this directly affects the service life of the bearing.
Greasing bearings
8.
Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. A high quality lubricating grease, such as 3HAB 3537-1, should be used.
9.
Grooved ball bearings should be greased on both sides.
Product Manual IRB 2400 5
General Description Repairs
10. Tapered roller bearings and axial needle bearings should be greased when they are split.
11. Normally the bearings should not be completely filled with grease. However, if there is space on both sides of the bearing, it can be filled completely with grease when it is fitted, as surplus grease will be released from the bearing on start up.
12. 70-80% of the available volume of the bearing must be filled with grease during operation.
13. Make sure that the grease is handled and stored correctly, to avoid contamination.
1.3.2 Seals
1.
The most common cause of leakage is incorrect installation.
Rotating seals
2.
The seal surfaces must be protected during transportation and assembly.
3.
The seals must either be kept in their original packages or be protected well.
4.
The seal surfaces must be inspected before installation. If the seal is scratched or damaged in such a way that it may cause leakage in the future, it must be replaced.
5.
The seal must also be checked before it is fitted to ensure that:
• the seal edge is not damaged (feel the edge with your finger nail)
• the correct type of seal is used (has a cut-off edge)
• there is no other damage.
6.
Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should be 2/3 filled with grease of the type 3HAB 3537-1. The rubber coated external diameter must also be greased.
7.
Seals and gears must be fitted on clean workbenches.
8.
Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping starts.
9.
Always use an assembling tool to fit the seal. Never hammer directly on the seal because this will cause it to leak.
10. Use a protective sleeve on the sealing edge during assembly, when sliding over threads, key-ways, etc.
6 Product Manual IRB 2400
Repairs General Description
Flange seals and static seals
11. Check the flange surfaces. The surface must be even and have no pores. The evenness can be easily checked using a gauge on the fitted joint (without sealing compound).
12. The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause leakage.
13. The surfaces must be cleaned properly in the manner recommended by ABB
ROBOTICS.
14. Distribute the sealing compound evenly over the surface, preferably using a brush.
15. Tighten the screws evenly around the flange joint.
16. Make sure that the joint is not subjected to loading until the sealing compound has attained the hardness specified in the materials specification.
O-rings
17. Check the O-ring grooves. The grooves must be geometrically correct, without pores and free of dust and grime.
18. Check the O-ring for surface defects and burrs, and check that it has the correct shape, etc.
19. Make sure the correct O-ring size is used.
20. Tighten the screws evenly.
21. Defective O-rings and O-ring grooves must not be used.
22. If any of the parts fitted are defective, they will cause leakage.
Grease the O-ring with 3HAB 3537-1 before fitting it.
Product Manual IRB 2400 7
General Description Repairs
1.4 Instructions for tightening screw joints
General
It is extremely important that all screw joints are tightened using the correct torque.
Application
The following tightening torques must be used for all screw joints made of metallic materials – unless otherwise specified in the text.
The instructions do not apply to screw joints made of soft or brittle materials.
For screws with a property class higher than 8.8, the same specifications as for class
8.8. are applicable, unless otherwise stated.
Screws treated with Gleitmo
All screws in the manipulator that are tightened to a specified torque are treated with
Gleitmo.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.
Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000.
When screwing in new screws without Gleitmo, these should first be lubricated with
Molycote 1000 and then tightened to the specified torque.
Assembly
Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote
1000 should only be used when specified in the text.
Screws sized M8 or larger should be tightened with a torque wrench, if possible.
Screws sized M6 or smaller may be tightened to the correct torque by personnel with sufficient mechanical training, without using torque measurement tools.
8 Product Manual IRB 2400
Repairs General Description
1.5 Tightening torques
1.5.1 Screws with slotted or cross recessed head
Dimension
M 2.5
M 3
M 4
M 5
M 6
Tightening torque - Nm
Class 4.8
“Dry”
0.25
0.5
1.2
2.5
5.0
1.5.2 Screws with hexagon socket head
Dimension
M 5
M 6
M 8
M 10
M 12
M 16
Tightening torque - Nm
Class 8.8
“Dry”
Class 10.9
Molycote 1000
Gleitmo 610
6
10
24
47
82
200
28
55
95
235
Class 12.9
Molycote 1000
Gleitmo 610
15
35
70
120
300
Product Manual IRB 2400 9
General Description Repairs
10 Product Manual IRB 2400
Repairs Axis 1
2 Axis 1
2.1 Replacing the motor for axis 1
See foldouts 1 and 5 in the list of spare parts.
The motor and the drive gear constitute one unit.
To dismantle:
1.
Remove the cover of the connection box.
2.
Loosen connectors R3.MP1 and R3.FB1.
3.
Remove the connection box by unscrewing <5/137>.
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing <1/9>.
To assemble:
6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Mount the O-ring <1/6>.
8.
Install the motor, tighten screws <1/9> using a torque of 2 Nm.
Note the position of the motor
9.
Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3.MP1 connector.
10. Mount tool no. 3HAB 7887-1 at the rear of the motor.
11. Turn the motor shaft a couple of turns, with help of the tool.
12. Place the tip of a dial indicator against the scribed mark on the measuring tool.
The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft.
13. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.
14. Pull gently in one direction. Note the reading. (The gear must not turn.)
Product Manual IRB 2400 11
Axis 1 Repairs
15. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.
16. Tighten screw <1/9> with a torque of 15 Nm.
17. Fill with oil. See chapter 10, Oil change in gearboxes.
18. Connect the cabling.
19. Calibrate the robot as specified in chapter 11, Calibration.
Tightening torque:
Motor attaching screws, item 9: 15 Nm
2.2 Changing the gearbox
Axis 1 gearbox is of the conventional type, manufactured with high precision, and together with the gearboxes for axes 2 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note:
If there is reason to change a gearbox on any of the axes 1, 2 or 3, then the whole unit must be changed.
See foldouts 1, 2 and 3 in the list of spare parts.
To dismantle:
1.
2.
Remove the tie rod as described in chapter 4.4, Changing the tie rod.
3.
Dismantle the upper arm as described in chapter 4.5, Dismantling the complete upper arm.
4.
Remove the parallel arm as described in chapter 4.3, Dismantling the parallel arm.
5.
Dismantle the lower arm as described in chapter 3.3, Dismantling the lower arm.
6.
Remove the motors on axes 1, 2 and 3 as described in sections chapter 2.1, Replac-
ing the motor for axis 1, chapter 3.1, Changing the motor for axis 2 and chapter 4.1,
Changing the motor for axis 3.
7.
Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate <3/102>.
Make sure that the foot is stable.
12 Product Manual IRB 2400
Repairs Axis 1
8.
Undo screws <1/3>.
9.
Separate the base from the gearbox unit.
To assemble:
10. Place a new gearbox unit on the table.
11. Raise the base.
12. Screw in the screws <1/3> together with their washers <1/4>. Tighten using a torque of 54 Nm.
13. Replace the bottom plate <3/102> using screws <3/120>.
14. Turn the base.
15. Replace the lower arm as described in chapter 3.3, Dismantling the lower arm
16. Replace the parallel arm as described in chapter 4.3, Dismantling the parallel arm.
17. Replace the upper arm as described in chapter 4.5, Dismantling the complete upper arm.
18. Replace the cabling as described in chapter 8, Cabling and Measuring board.
19. Replace the tie rod as described in chapter 4.4, Changing the tie rod.
20. Calibrate the robot as described in chapter 11, Calibration.
Tightening torque:
Screwed joint of base/gearbox unit, item <1/3>: 54 Nm
2.3 Replacing the mechanical stop
See foldout 1 in the list of spare parts.
If the stop pin is bent, it must be replaced.
1. Remove screw <134>.
2. Lift the stop away.
To assemble:
3. Place a new stop in position.
4. Tighten screw <134>.
Product Manual IRB 2400 13
Axis 1 Repairs
14 Product Manual IRB 2400
Repairs Axis 2
3 Axis 2
3.1 Changing the motor for axis 2
See foldouts 1 and 5 in the list of spare parts.
The motor and the drive gear constitute one unit.
To dismantle:
Lock the arm system before dismantling the motor; the brake is located in the motor.
1.
Remove the cover of the connection box.
2.
Loosen connectors R3.MP2 and R3.FB2.
3.
Remove the connection box by unscrewing <5/137>.
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing <1/8, 1/9>. N.B. The oil will start to run out.
To assemble:
6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Mount the O-ring <1/6>.
8.
Install the motor, tighten screws <1/8>, 1/9> using a torque of 2 Nm.
Note the position of the motor and the location of the two screws <1/8>.
9.
Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3.MP1 connector.
10. Mount tool no. 3HAB 7887-1 at the rear of the motor.
11. Turn the motor shaft a couple of turns, with help of the tool.
12. Place the tip of a dial indicator against the scribed mark on the measuring tool.
The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft.
13. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.
14. Pull gently in one direction. Note the reading. (The gear must not turn.)
Product Manual IRB 2400 15
Axis 2 Repairs
15. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.
16. Tighten screw <1/8, 1/9> with a torque of 15 Nm.
17. Fill with oil. See chapter 10, Oil change in gearboxes.
18. Connect the cabling.
19. Calibrate the robot as specified in chapter 11, Calibration.
Tightening torque:
The motor’s fixing screws, item 8, 9: 15 Nm
3.2 Changing the gearbox
Axis 2 gearbox is of a conventional type, manufactured with high precision, and together with the gearbox for axes 1 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note:
If there is reason to change a gearbox on any of the axes 1, 2 or 3, the whole unit must be changed.
To dismantle:
See chapter 2.2, Changing the gearbox.
3.3 Dismantling the lower arm
See foldout 2 in the list of spare parts.
To dismantle:
1.
Remove the cabling down to axis 1 as in chapter 8, Cabling and Measuring board.
2.
Dismantle the upper arm as in chapter 4.5, Dismantling the complete upper arm.
3.
Attach the crane to the lower arm.
4.
Remove the parallel arm as in chapter 4.3, Dismantling the parallel arm.
5.
Loosen screws <12>.
6.
Take off the lower arm.
16 Product Manual IRB 2400
Repairs Axis 2
To assemble:
7.
Transfer the damping element and calibration marking to the new lower arm.
8.
Lift the lower arm into position.
9.
Fix the lower arm to gearbox 2 using screws <12> and tighten to a torque of
68 Nm.
To prevent clicking during operation of the robot, grease the bearing seat of the parallel arm in the lower arm.
10. Mount the parallel arm as in chapter 4.3, Dismantling the parallel arm.
11. Replace the upper arm as in chapter 4.5, Dismantling the complete upper arm.
12. Replace the cabling as in chapter 8, Cabling and Measuring board.
13. Calibrate the robot as in chapter 11, Calibration.
Tightening torque:
Screwed joint of lower arm/gearbox 2, item <12>: 68 Nm
Product Manual IRB 2400 17
Axis 2 Repairs
3.4 Changing the bearing in the lower arm
See foldouts 1, 2 and 3 in the list of spare parts.
To dismantle:
1.
Dismount the tie rod as in chapter 4.4, Changing the tie rod.
Loosen the screws <3/135> so that the cables can moved a bit.
2.
Attach a hoist to the parallel arm.
3.
Unscrew screws <2/17> which hold the parallel arm to gearbox 3 and remove it.
4.
Remove the bearing from the parallel arm.
To assemble:
5.
Mount V-ring <2/19>.
6.
Mount seal ring <2/21> on the parallel arm.
Heat up the bearing <2/20> to 170 o
C before mounting it on the parallel arm.
7.
Fit a new bearing <2/20> on the parallel arm.
8.
Mount the other seal ring <2/21> on the parallel arm.
9.
Replace the screws <2/17> and tighten to a torque of 68 Nm.
10. Mount the tie rod as in chapter 4.4, Changing the tie rod.
11. Mount screws <3/135> and tighten.
12. Calibrate the robot as in chapter 11, Calibration.
Tightening torque:
Screwed joint of parallel arm/gearbox 3, item <2/17>: 68 Nm
18 Product Manual IRB 2400
Repairs Axis 3
4 Axis 3
4.1 Changing the motor for axis 3
See foldouts 1 and 5 in the list of spare parts.
The motor and the drive gear constitute one unit.
To dismantle:
Lock the arm system before dismantling the motor; the brake is located in the motor.
1.
Remove the cover of the connection box.
2.
Loosen connectors R3.MP3 and R3.FB3.
3.
Remove the connection box by unscrewing <5/137>.
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing <1/8, 1/9>. N.B. The oil will start to run out.
To assemble:
6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Mount the O-ring <1/6>.
8.
Install the motor, tighten screws <1/8, 1/9> using a torque of 2 Nm.
Note the position of the motor and the location of the two screws <1/8>.
9.
Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3.MP1 connector.
10. Mount tool no. 3HAB 7887-1 at the rear of the motor.
11. Turn the motor shaft a couple of turns, with help of the tool.
12. Place the tip of a dial indicator against the scribed mark on the measuring tool.
The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft.
13. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.
14. Pull gently in one direction. Note the reading. (The gear must not turn.)
Product Manual IRB 2400 19
Axis 3 Repairs
15. Then gently knock in the other direction and note the reading. The difference in readings = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.
16. Tighten screw <1/8, 1/9> with a torque of 15 Nm.
17. Fill with oil. See chapter 10, Oil change in gearboxes.
18. Connect the cabling.
19. Calibrate the robot as specified in chapter 11, Calibration.
Tightening torque:
The motor fixing screws, item 8, 9: 15 Nm
4.2 Changing the gearbox
Axis 3 gearbox is of a conventional type, manufactured with high precision, and together with the gearboxes for axes 1 and 3, forms a complete unit.
The gearbox is not normally serviced or adjusted.
Note:
If there is reason to change a gearbox on any of the axes 1, 2 or 3, then the whole unit must be changed.
To dismantle:
See chapter 2.2, Changing the gearbox.
4.3 Dismantling the parallel arm
See foldouts 1, 2 and 3 in the list of spare parts.
To dismantle:
1.
Dismount the tie rod as in chapter 4.4, Changing the tie rod.
Loosen the screws <3/135> so that the cables can moved a bit.
2.
Unscrew screws <2/17> which fix the parallel arm to gearbox 3.
3.
Remove the bearing and sealings from the parallel arm.
To assemble:
4.
Mount V-ring <2/19>.
20 Product Manual IRB 2400
Repairs Axis 3
5.
Mount seal ring <2/21> on the parallel arm.
Heat up the bearing <2/20> to 170 o
C before mounting it on the parallel arm.
6.
Fit a new bearing <2/20> to the parallel arm.
7.
Mount the other seal ring <2/21> on the parallel arm.
8.
Replace the screws <2/17> and tighten to a torque of 68 Nm.
9.
Mount the tie rod as in chapter 4.4, Changing the tie rod.
10. Mount screws <3/135> and tighten.
11. Calibrate the robot as in chapter 11, Calibration.
Tightening torque:
Screwed joint of parallel arm/gearbox 3, item <2/17>: 68 Nm
4.4 Changing the tie rod
See foldouts 1 and 8 in the list of spare parts.
To dismantle:
Lock the upper arm in a horizontal position with the help of a crane or similar.
1.
Unscrew screws <34> and <8/49>.
2.
Remove washers <33, 8/50> and seals <35, 8/48>.
3.
Insert a screw in the centre, to be used as a support.
4.
Use a puller to pull out the tie rod <8/43>.
5.
Change the bearings <8/44> and seals <8/45>.
6.
Move the mechanical stop.
To assemble:
7.
Make sure you replace the rod the correct way up. See foldout 1.
8.
Mount new bearings <8/44> and seals <8/48, 8/45>. Use tool 3HAB 6324-1.
9.
Mount the tie rod on the manipulator using tool 3HAB 6331-1.
10. Mount washers <33, 8/49> and lock screws <34, 8/49> with Loctite 242.
Product Manual IRB 2400 21
Axis 3 Repairs
4.5 Dismantling the complete upper arm
See foldouts 1 and 8 in the list of spare parts.
To dismantle:
Attach a crane to the upper arm.
1.
Dismount the tie rod as in chapter 4.4, Changing the tie rod.
2.
Loosen the connectors of the motors of axes 4, 5 and 6.
3.
Disconnect the connection box from the motors.
4.
Remove the covers <1/57>.
5.
Undo the KM nuts <1/54>.
6.
Remove screws <1/56>.
7.
Pull out the shaft. Use tool 3HAB 9009-1. Mark the shafts (left, right).
To assemble:
8.
Mount sealings <8/41> in the upper arm.
9.
Mount the inner ring of the bearings <8/42> on shafts <1/55>.
Use tool no. 3HAB 6464-1.
10. Raise the upper arm into the assembly position.
11. Install shaft spindles <1/55> (both sides).
12. Insert screws <1/56> and tighten with torque 90 Nm.
The following procedure must be performed within 10 minutes, before the Loctite
starts to harden.
13. Apply Loctite 242 on the KM-nuts.
14. Tighten the KM-nut on the left side first (robot seen from behind) so that the bearing comes against the collar.
15. Unscrew the KM-nut and then tighten with a torque of 35 Nm.
16. Tighten the KM-nut on the right side, move the upper arm up and down at the same time, until there is no play.
17. Unscrew the nut again.
18. Tighten the KM-nut with a torque of 35 Nm.
22 Product Manual IRB 2400
Repairs Axis 3
19. Mount the covers <1/57>.
Push in a strap from the other under the sealing, so that the air can go out.
20. Mount the tie rod as in chapter 4.4, Changing the tie rod.
21. Mount the sync. plate for axis 3.
22. Reconnect the connection boxes and the cabling.
23. Calibrate the robot as in chapter 11, Calibration.
Tightening torque:
KM nut, item <1/54>: 35 Nm
Product Manual IRB 2400 23
Axis 3 Repairs
24 Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400/10/16)
5 Axes 4-6 (IRB 2400/10/16)
5.1 Replacing the motor
See foldouts 7 and 8 in the list of spare parts.
The motor and the drive gear constitute one unit.
To dismantle:
Valid for axes 4-6.
Lock the arm system before dismantling the motor; the brake is located in the motor.
1.
Remove the cover of the connection box.
2.
Drain the oil in the gearbox. Open plug <33> or position the upper arm vertical.
3.
Loosen connectors R3.MP(4,5,6) and R3.FB(4,5,6).
4.
Remove the connection box by unscrewing <7/58>.
5.
Note the position of the motor before removing it.
6.
Loosen the motor by unscrewing <7/28>.
To assemble:
Valid for axis 4
7.
Check that the assembly surfaces are clean and the motor unscratched.
8.
Mount O-ring <7/27>.
9.
Mount tool no. 3HAB 7887-1 at the rear of the motor.
10. Release the brake in motor for axis 4 by applying 24 VDC to terminals 7(+) and 8 on the R3.MP4 connector.
11. Seek up the smallest play by turning the motor shaft 6 turns and thereby find the area with the smallest play within this range.
12. Push the motor radially so that the play becomes minimal within one motor turn, without the gear “chewing”.
13. Fill with oil if drained. See chapter 10, Oil change in gearboxes.
14. Connect the cabling.
Product Manual IRB 2400 25
Axes 4-6 (IRB 2400/10/16) Repairs
15. Calibrate the robot as specified in chapter 11, Calibration.
Valid for axis 5
7.
Check that the assembly surfaces are clean and the motor unscratched.
8.
Mount O-ring <7/27>.
9.
Mount tool no. 3HAB 7887-1 at the rear of the motor.
10. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of
90°, totally one whole turn, and thereby find the area where the play for motor 5 becomes smallest.
11. Turn the motor for axis 5 one full turn at a time, totally 5 turns. Find where the smallest play is within this area.
12. Push the motor radially so that the play becomes minimal within one motor turn, without the gear “chewing”.
13. Fill with oil if drained. See chapter 10, Oil change in gearboxes.
14. Connect the cabling.
15. Calibrate the robot as specified in chapter 11, Calibration.
Valid for axis 6
7.
Check that the assembly surfaces are clean and the motor unscratched.
8.
Mount O-ring <7/27>.
9.
Mount tool no. 3HAB 7887-1 at the rear of the motor.
10. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of
90°, totally one whole turn, and thereby find the area where the play for motor 6 becomes smallest.
11. Turn the motor for axis 5 one full turn at the time, totally 5 turns. Find the smallest play for axis 6 within this area.
12. Turn the motor for axis 6 one full turn at a time, totally 3 turns. Find the smallest play for axis 6 within this area.
13. Push the motor radially so that the play becomes minimal within one motor turn, without the gear “chewing”.
14. Fill with oil if drained. See chapter 10, Oil change in gearboxes.
15. Connect the cabling.
16. Calibrate the robot as specified in chapter 11, Calibration.
26 Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400/10/16)
Tightening torque:
The motor’s fixing screws, item 28: 11 Nm
5.2 Dismounting the wrist
The wrist, which includes axes 5 and 6, is a complete unit comprising drive units and gearboxes. It is a replacement unit of complex design and should not normally be serviced on-site. Instead it should be sent to ABB Flexible Automation for service etc.
ABB Robotics recommends its customers to carry out only the following servicing and repair work on the wrist.
• Change the oil as shown in the table in chapter 10, Oil change in gearboxes.
See foldout 7 in the list of spare parts.
To dismantle:
1.
Remove the oil plugs on the wrist and drain it as described in chapter 10, Oil change in gearboxes.
2.
Undo screws <20> and remove the wrist.
To assemble:
3.
Mount O-ring <19> with grease on the wrist.
4.
Run the upper arm to a vertical position, wrist side pointing upwards.
5.
Mount the wrist. Do not tighten the screws.
6.
Release the brakes on axes 5 and 6 (one at the time) and mount tool 3HAB 7887-1 at the rear of the motor.
7.
Push the wrist, as shown in Figure 1, to locate the smallest play in the same way as
for adjustment of play when changing motors for axes 5 and 6, see
chapter 5.1, Replacing the motor.
Upper arm seen from the front
Gears on drive shaft unit axes 5 and 6
Gears on the wrist
Figure 1 Adjusting the play for the wrist.
Product Manual IRB 2400 27
Axes 4-6 (IRB 2400/10/16)
8.
Tighten screws <20> with washer <21> to a torque of 17 Nm.
9.
Check the play by moving axes 5 and 6 by hand.
10. Fill with oil. See chapter 10, Oil change in gearboxes.
11. Calibrate the robot as in chapter 11, Calibration.
Tightening torque:
Screwed joint of wrist/tubular shaft, item <20>: 17 Nm
Repairs
5.3 Dismounting the mechanical stop for axis 4
See foldout 7 in the list of spare parts.
To dismantle:
1.
Undo screws <32> and remove the stop for axis 4.
2.
Rotate axis 4 so that the damper <30> becomes visible, and pull it out.
To assemble:
3.
Mount damper <30>.
4.
Put sealing compound Loctite 574 on the stop.
5.
Mount stop for axis 4 with screws <32> and tighten with a torque of 15 Nm.
Tightening torque:
Screwed joint of stop/arm housing, item <32>: 15 Nm
28 Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400L)
6 Axes 4-6 (IRB 2400L)
6.1 Axis 4
6.1.1 Changing the motor
See foldouts 9 and 10 in the list of spare parts.
The motor and the drive gear constitute one unit.
Position the arm system in such a way that the motor of axis 4 points upwards.
To dismantle:
1.
Remove the cover of the motor.
2.
Loosen connectors R3.MP4 and R3.FB4.
3.
Remove the connection box by unscrewing <10/29>.
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing <9/17>.
To assemble:
6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Put O-ring <9/18> on the motor.
8.
Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP4 connector.
9.
Install the motor, tighten screws <9/17> to a torque of approximately 2 Nm.
Note the position of the motor
10. Adjust the position of the motor in relation to the drive in the gearbox.
11. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.
12. Make sure there is a small clearance.
13. Unscrew one screw at a time, apply Loctite 242 and tighten to a torque of
4.1 Nm ±10%.
14. Connect the cabling.
15. Calibrate the robot as in 11, Calibration.
Product Manual IRB 2400 29
Axes 4-6 (IRB 2400L) Repairs
30
Tightening torque:
The motor’s fixing screws, item <9/17>: 4.1 Nm ±10%
Tool:
Crank tool for checking the play: 3HAB 1201-1
6.1.2 Changing the intermediate gear including sealing
See foldout 9 in the list of spare parts.
To dismantle:
1.
Dismantle the wrist as in 6.2, The Wrist and Axes 5 and 6.
2.
Dismantle the drive mechanism as in
6.2.2, Changing the drive shaft unit, gear belts or motors.
3.
Dismantle the motor of axis 4 as in 6.1.1, Changing the motor.
4.
Remove the cover <28>.
5.
Undo screws <12> fixing the large drive gear <10> and dismantle it.
N.B. Put the shims in a safe place.
6.
Undo screws <25>.
7.
Push the intermediate gear out of the arm housing.
To assemble:
8.
Grease the seating of the arm housing to provide radial sealing.
9.
Push the gear unit down into the arm housing.
10. Screw in screws <25> together with their washers <24> and pull the gear down.
11. Mount the drive gear <10> using screws <12> and tighten to a torque of
8.3 Nm ±10%.
N.B. Do not forget to insert shims <7, 8, 9> under the drive gear.
12. Tighten screws <25> to a torque of approximately 5 Nm.
13. Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear.
14. Then tighten screws <25> to a torque of 20 Nm ±10%.
15. Check the clearance in relation to the tightening torque.
Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400L)
16. Clean the surfaces of the armhousing and cover. Apply Loctite 574 as sealing.
17. Replace the cover <28> using screws <29>. Use a drop of Loctite 242.
18. Position the manipulator so that the tubular shaft points upwards.
19. Fill (30 ml) oil into the gear of axis 4. See Maintenance.
20. Install the motor of axis 4 as in 6.1.1, Changing the motor.
21. Install drive mechanism <15> as in 6.2.2, Changing the drive shaft unit, gear belts or motors.
22. Replace the wrist as in 6.2, The Wrist and Axes 5 and 6.
23. Calibrate the robot as in 11, Calibration.
Tightening torque:
Screws for the large drive gear, item <12>: 8.3 Nm ±10%
Screws for the intermediate gear of axis 4, item <25>: 20 Nm ±10%
6.1.3 Changing the drive gear on the tubular shaft
See foldout 9 in the list of spare parts.
To dismantle:
1.
Dismantle the wrist as in 6.2, The Wrist and Axes 5 and 6.
2.
Dismantle the drive mechanism as in 6.2.2, Changing the drive shaft unit, gear belts or motors.
3.
Dismantle the motor of axis 4 as in 6.1.1, Changing the motor.
4.
Remove the cover <28>.
5.
Unscrew screws <25> that hold the intermediate gear in place.
6.
Unscrew screws <12> that hold the large drive gear <10> and then dismantle it.
N.B. Put the shims from under the drive gear in a safe place.
Product Manual IRB 2400 31
Axes 4-6 (IRB 2400L)
To assemble:
Shim between drive gear <10> and the rear bearing <4>.
Shim thickness = B - A + 0.05 mm, see Figure 2.
Repairs
32
Figure 2 Measuring the shim thickness of the drive gear of axis 4.
7.
Install the drive gear using screws <12> and tighten to a torque of 8.3 Nm ±10%.
N.B. Do not forget the shims.
8.
Adjust the intermediate gear as in
6.1.2, Changing the intermediate gear including sealing.
9.
Lubricate the drive gear with grease (30 g).
10. Install the motor of axis 4 as in 6.1.1, Changing the motor.
11. Clean the surfaces of the cover. Apply Loctite 574 as sealing
12. Replace the cover <28> using screws <29>. Lock by using a drop of Loctite 242.
13. Mount the drive mechanism as in 6.2.2, Changing the drive shaft unit, gear belts or motors.
14. Mount the wrist as in 6.2.1, Dismantling the wrist.
15. Calibrate the robot as in 11, Calibration.
Tightening torque:
Screws of drive gear, item <12>: 8.3 Nm ±10%
Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400L)
6.1.4 Changing bearings of the tubular shaft
See foldout 9 in the list of spare parts.
To dismantle:
1.
Dismantle the drive gear as in
6.1.3, Changing the drive gear on the tubular shaft.
2.
Push out the tubular shaft.
To assemble:
3.
Fit a new bearing <4> on the tubular shaft using tool 6896 134-V.
4.
Push the tube into the housing of the upper arm.
5.
Insert the rear bearing <4> using tool 6896 134-JB.
6.
Mount the drive gear as in
6.1.3, Changing the drive gear on the tubular shaft.
7.
Calibrate the robot as in Chapter 9, Calibration.
Tools:
Pressing tool for front bearing: 6896 134-V
Pressing tool for rear bearing: 6896 134-JB
6.2 The Wrist and Axes 5 and 6
The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears. It is of such a complex design that it is not normally serviced on-site, but should be sent to ABB Flexible Automation to be serviced.
ABB Robotics recommends its customers to carry out only the following servicing and repair work on the wrist.
• Change the oil according to the table in the chapter on maintenance.
Product Manual IRB 2400 33
Axes 4-6 (IRB 2400L) Repairs
34
6.2.1 Dismantling the wrist
See foldouts 9 and 11 in the list of spare parts.
To dismantle:
1.
Remove the 2 plugs on the rear of the wrist.
2.
Release the brake in axes 5 and 6.
3.
Rotate axes 5 and 6 so that you can see screws <11/9> in the clamping sleeve through the hole.
4.
Disconnect the clamping sleeve.
5.
Undo screws <9/37> and washers <9/13>. Remove the wrist.
To assemble:
6.
Clean the surface of the tubular shaft.
7.
Apply Loctite 574 all around.
8.
Mount the wrist, tighten screws <9/37> to a torque of 8.3 Nm ±10%.
9.
Screw the clamping sleeves together using screws <11/9> to a torque of 5.7 Nm.
10. Replace the plugs.
11. Mount the cover at the motor side of axis 5-6.
12. Calibrate the robot as in 11, Calibration.
Tightening torque:
Screwed joint of wrist/tubular shaft, item <9/37>: 8.3 Nm ±10%
Screwed joint clamping sleeves, item <11/9>: 5.7 Mn ±10%
6.2.2 Changing the drive shaft unit, gear belts or motors
See foldouts 9 and 11 in the list of spare parts.
To dismantle:
1.
Dismantle the wrist as in section 6.2.1, Dismantling the wrist.
2.
Loosen the connection box and disconnect the connectors on the motors of axes 5 and 6. Make a note of the motor no. on the motors, to simplify the reconnection.
3.
Undo screws <9/14>.
Product Manual IRB 2400
Repairs Axes 4-6 (IRB 2400L)
4.
Squeeze the drive shafts (<11/1>) together at the tip of the tubular shaft, in order that they can pass through the tube.
5.
Pull out the complete drive mechanism of axes 5 and 6.
6.
Undo screw <11/5> and nuts <11/4>, holding the motors and remove both motors.
7.
Undo screw <11/5> and remove the motor plate <11/3> and screw <11/9>.
8.
Remove the gear belts.
To assemble:
9.
Install the belts <11/7>.
10. Mount the plate <11/3> using screws <11/5> and washers <11/6>.
N.B. Do not forget the nuts on the motors.
11. Install the motors.
12. Push the motors sideways to tighten the belts. Use tool 3HAA 7601-050. Place the round post of the tool into the motor pulley and let the cam press to the outer diameter of the large pulley. Tighten screws <11/5> to a torque of 4.1 Nm.
13. Rotate the drive shafts. Check the tension on the belt.
14. Install the drive mechanism in the tubular shaft. Do not forget the rubber damper
<9/11>.
15. Tighten screws <9/14> to a torque of 8.3 Nm.
16. Install the cabling and mount the cover to motors axes 5 and 6.
17. Mount the wrist according to section 6.2.1, Dismantling the wrist.
18. Calibrate the robot as in chapter 11, Calibration.
N.B. It is sufficient to only calibrate axes 5 and 6, if the other axes have been positioned correctly by running the CAL2400 program. Do not forget to change the resolver offset values on the label under the rear cover on the robot base.
Tightening torque:
Screwed joint of the drive mechanism, item <9/14>: 8.3 Nm ±10%
Screws holding motors, item <11/5>: 4.1 Nm ±10%
Product Manual IRB 2400 35
Axes 4-6 (IRB 2400L) Repairs
6.2.3 Changing the motor or driving belt of axes 5 and 6
See foldout 11 in the list of spare parts.
To dismantle:
1.
Dismantle the wrist as in section 6.2.1, Dismantling the wrist.
2.
Dismantle the drive mechanism as in
6.2.2, Changing the drive shaft unit, gear belts or motors.
3.
Undo screws <5> and nuts <4>. Remove the appropriate motor.
4.
If the driving belt is to be changed, both motors must be removed before plate can be removed.
5.
Undo screws <5> and washers <6>. Remove plate <6>.
To assemble:
6.
Install the driving belts.
7.
Mount the plate <3> using screws <5> and washers <6>.
N.B. Do not forget the nuts of the motors.
8.
Install the motors.
9.
Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050.
Tighten screws <15> to a torque of 4.1 Nm.
10. Rotate the drive shafts. Check the tension on the belt.
11. Install the drive mechanism as in
6.2.2, Changing the drive shaft unit, gear belts or motors.
12. Mount the wrist as in section 6.2.1, Dismantling the wrist.
13. Calibrate the robot as in 11, Calibration.
Tightening torque:
Screws for motors and plate, item <15>: 4.1 Nm.
Tool:
To adjust the belt tension: 3HAA 7601-050
36 Product Manual IRB 2400
Repairs Push-button unit for brake release
7 Push-button unit for brake release
7.1 General description
See foldout 4.
The push-button unit <121> is located on the flange plate on the base and is used to quickly and safely release the axis brakes manually, when doing various types of work on and around the robot. It is then also possible to move the arms of the robot manually, when this is necessary.
When the controller or certain parts of the cabling have been disconnected, the brakes can be released using a separate 24 VDC power source. The power is connected as described in one of the following two alternatives:
1. Connector R1.MP on the robot base.
+ 24 V to R1.MP. B8
0 V to C10
0 V C10
+24 V B8
NOTE!
Be careful not to interchange the 24 V and 0 V pins.
If they are mixed up, damage can be caused to the brake release unit and the system board.
Incorrect connections can cause all brakes to be released simultaneously
2. Directly to the cable of the respective brake.
The connection must be made in accordance with the wiring diagram for the mechanical robot.
Note: when power is connected directly to the brake cable, the brake will be released immediately the power is switched on. This can cause some unexpected robot movements!
The push-button unit is equipped with six buttons for controlling the axis brakes. The buttons are numbered with the axes numbers. The unit is located underneath a rubber cover in the cover. The brakes are of electro-mechanical type and are released when voltage is applied. To release the brake on a particular axis, push the appropriate button and keep it depressed. The brake will function again as soon as the button is released.
Product Manual IRB 2400 37
Push-button unit for brake release Repairs
To dismantle:
See foldout 4.
When replacing the push-button unit <121>, the complete unit should be replaced as follows:
1. Position the lower arm at one of its end positions and lower the upper arm to its end position.
Note: the robot must not be in the STANDBY MODE! This applies for all types of cabling work.
2. Cut the power to the robot by turning off the main switch.
3. Remove the cover.
4. Disconnect the connectors on the cabling to the push-button unit <121>.
5. Remove the push-button unit by undoing the screws.
6. Refit a new unit in the reverse order.
38 Product Manual IRB 2400
Repairs Cabling and Measuring board
8 Cabling and Measuring board
8.1 Changing serial measuring board
See foldout 5 in the list of spare parts.
Note!
When working with the serial measurement board it is important that a wrist strap is used, to avoid ESD faults.
To dismantle:
1.
Remove the flange plate on the base.
2.
Cut straps.
3.
Unscrew the serial measuring board <115> using nuts <118>.
4.
Remove the board and loosen the contacts.
To assemble:
5.
Assemble in the reverse order.
8.2 Changing the cabling in axes 1,2 and 3
See foldouts 3 and 4 in the list of spare parts.
The cables to motor axes 1, 2 and 3 are handled as one unit.
To dismantle:
1.
Remove the cover of the connections boxes.
2.
Loosen the flange plate on the base.
3.
Loosen connectors R1.MP, R2.FB1-3. Loosen the serial measurement board.
4.
Remove cable straps <3/119>. Loosen nuts <5/118>. The lower bracket need not to be removed.
5.
Detach the cable guides <3/109>.
6.
Loosen covers <3/112> and screws <3/137>. Loosen the connectors.
7.
Disconnect the connection boxes in the motors.
Product Manual IRB 2400 39
Cabling and Measuring board
8.
Loosen screws <3/120>.
9.
Feed the cabling up through the middle of axis 1.
To assemble:
10. Assemble in the reverse order.
Repairs
8.3 Changing the cabling in axes 4, 5 and 6
See foldouts 3 and 4 in the list of spare parts.
The cables to motor axes 4, 5 and 6 and for customer signals are handled as one unit.
To dismantle:
1.
Remove the cover of the motors.
2.
Loosen the flange plate <3/104>.
3.
Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connector
R1.CS, R1.CP and R2.FB4-6, and the air hose in the base. (To reach R2.FB4-6, the serial measurement board can be removed.)
4.
Remove cable straps <3/119>. Loosen nuts <5/118>.
5.
Loosen screws <3/120> and cable brackets <3/108> between gears 2 and 3 and cut the tie around them.
6.
Feed the cabling and air hose up through axis 1.
7.
Loosen the cable bracket on the lower arm and undo screws <3/116>.
8.
Loosen connectors R3.MP4, R3.MP5, R3.MP6, R3.FB4, R3FB5 and R3FB6.
Loosen the connection box from the motors.
9.
Loosen screw <3/137> to remove cable guide <3/111>.
To assemble:
10. Assemble in the reverse order.
8.4 Changing the signal cabling axis 4, option 04y
To dismantle:
1.
Loosen the two plates, two M6 + three M8 screws.
40 Product Manual IRB 2400
Repairs Cabling and Measuring board
2.
Loosen the two holders around the tube shaft.
3.
Loosen the connectors at the rear of the upper arm.
To assemble:
4.
Apply transparent protection tape on the narrow part of the tube shaft. Remove dirt
and grease from the surface first, see Figure 3.
Tape
Wrist side
Figure 3 Location of protection tape.
5.
Run axis 4 to its calibration position, 0 degrees.
6
Fasten the front (outer) plate with two M6 screws, see Figure 4.
7.
Then fasten the rear (inner) plate with three M8 screws, see Figure 4.
2 M6
3 M8
Figure 4 Location of screws.
8.
Slowly rotate axis 4 clockwise to its stop position. Check all the time that the cables are not fully stretched.
NOTE! If this should happen, stop the rotation and let out more cable from the rear cable holder. This is done by loosening the grey holders and pushing out the cables by hand.
9.
Finish the rotation. NOTE! Leave the rear cable holder open (do not tighten).
Product Manual IRB 2400 41
Cabling and Measuring board Repairs
10. Mount the front holder around the tube shaft first. Let the black plastic hose around
the arm go through the foot of the fixing ring, see Figure 5. Applies to both fixing
rings.
Figure 5 Mounting the fixing rings on the tube shaft.
11. Move axis 4 from one extreme limit to the other and back again.
Carefully check the behaviour of the cables! They must not be fully stretched. The cables and air hose must not touch any moving parts of the arm. The fixing rings must be able to slide smoothly the whole time with no excessive pulling.
12. The length of the cables is now finely adjusted by pushing and pulling the cables through the inner holders, which are still loose.
13. When axis 4 is moving, no stretching of the cables should be felt.
14. Tighten the holders by hand. Do not use any tools.
15. Connect the connectors at the rear end of the upper arm.
16. Connect the air hose.
17. Fix the cables and air hose together with cable straps above the motors.
42 Product Manual IRB 2400
Repairs Balancing system
9 Balancing system
9.1 General description
See foldout 2.
The balancing system should not be opened or tampered with. Treat the balancing system as a replacement unit, i.e. replace it as a complete unit when necessary.
The purpose of the balancing system is to give balance to the lower arm. The cylinder is charged with nitrogen.
This closed system also prevents dirt etc. from entering the system.
To obtain maximum use of the robot’s excellent performance, it is essential that the gas spring is pressurised correctly. When the robot is in the calibration position,
(all axes 0 o
) the pressure should be as follows:
Temp. ( o C)
10
20
30
40
IRB 2400/10/16
Pressure
(± 3 bar)
Floor mounted
Inverted
155
160
165
171
164
170
176
182
IRB 2400L
Pressure
(± 3 bar)
Floor mounted
Inverted
145
150
155
160
164
170
176
182
9.2 Dismounting the balancing spring
To dismantle:
See foldout 2 and 6 in the list of spare parts.
1. Move the manipulator to the calibration position. Make a note of the pressure.
2. Check that the brakes are on, before releasing the pressure in the cylinder using the charging device no. 3HAB 5880-1.
3. Clean around the safety screw.
Product Manual IRB 2400 49
Balancing system Repairs
4. Remove the safety screw. Connect the hose on the charging device to the nitrogen tube.
Attach the screw fitting on the regulator to the balancing spring using the larger of the double handwheels.
5. Open the balancing spring valve carefully by screwing the smaller of the double handwheels inwards and clockwise.
6. The valve on the gas spring is easily damaged if the gas spring is emptied to quickly. When emptying the gas spring, open the valve by turning the small hand wheel carefully. When the gas start to stream out, open it just a little more. When the gas stream start to reduce, the valve can be opened a little more, repeat this every time the gas stream start to reduce.
It should take at least 2 minutes to empty the gas spring.
Warning! Large quantities of nitrogen gas in a small room can be toxic!
Warning! Direct contact with escaping gas can cause frost injuries!
7. Release the gas with the handwheel on the side.
8. When the gas has been discharged, close the valve with the handwheel and the balancing spring valve. Note, that the smaller of the double handwheels should be turned anticlockwise.
9. Remove the regulator housing and replace the safety screw.
10.Remove screw <26> and washer <27>.
11.Remove the shaft <25> in the lower end. Take care of the washers <28>.
12.Remove screw <31> in the upper end.
13 .Hold the balancing spring and push out the axis to the right.
To assemble:
14.Place the balancing spring piston rod attachment in position in the lower arm.
Note! Don’t forget washer <29>.
15.Mount screw <31> and tighten with torque of 68 Nm.
16.Place the balancing spring in position at the lower end.
17.Mount 3 plastic washers <28> on the left side.
18.Adjust with plastic washers on the other side so that the play is max. 1.5 mm / min >0 mm.
Note! The joint must not be tight, it must always be a small play in it.
19.Knock shaft <25> gently into position with a plastic hammer.
20.Mount screw <26> and washer <27>. Lock with Loctite 242.
50 Product Manual IRB 2400
Repairs Balancing system
21.It is important that the bearings on the rear and especially the front side of the gas spring are greased correctly:
Mount a greasing nipple and press in grease Optimol PDO in the right hole until
grease comes up through the left hole without air bubbles, see Figure 7
Grease shall be pressed out until no air bubbles are coming out
Grease shall be pressed out until no air bubble are coming out
Grease Optimol PD0
Grease Optimol PDO
Rear and front gas spring bearings
Rear and front gas spring bearings
Figure 7 Greasing of gas spring bearings.
22.Unscrew the safety screw. Let the valve remain in place (art. no. 3HAC 0640-1). If there is any leakage, replace the valve.
23.Attach the regulator housing to the balancing spring using the larger of the double handwheels.
24.Open the spring valve by screwing the smaller of the double handwheels inwards
(do not screw to the bottom).
25.Check that the gas valve is closed (lever at 90 o
to hose) before opening the nitrogen tube.
26.charge very slowly with gas to the pressure specified in the table above using the valve. The lower arm must be in a vertical position.
27.Close the nitrogen tube. Then close the spring valve by turning the smaller of the two double handwheels anticlockwise.
28.Empty the gas from the regulator and hose by opening the handwheel on the side and the gas valve on the hose. Close these two valves and remove the regulator housing.
29.Check that the valve does not leak before fitting the sealing washer and safety screw.
If there is any leakage, replace the valve.
Product Manual IRB 2400 51
Balancing system Repairs
9.3 Changing the valve in the balancing spring
Removal:
1. Release the pressure in the spring as described in chapter 9.2, Dismounting the balancing spring.
2. Unscrew the safety screw.
3. Lift out the valve using a pair of valve pliers no. 6808 0011-LE.
Refitting:
4. Fit the new valve (art. no. 3HAC 0640-1).
5. Screw in the safety screw.
6. Charge with gas as described in chapter 9.2, Dismounting the balancing spring.
52 Product Manual IRB 2400
Repairs Motor units
9 Motor units
9.1 General
Each axis of the manipulator has its own motor unit, comprising:
- a synchronous motor
- a brake (built into the motor)
- a feedback device.
There are a total of six motors mounted in the manipulator.
The power and signal cables are run to the respective motor from the cable connector points on the manipulator. The cables are connected to the motor units by connectors.
The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis. A brake, operated electromagnetically, is mounted on the rear end of the motor shaft and a pinion is mounted on its drive end. The brake releases when power is supplied to the electromagnets.
N.B.
There is a feedback device mounted on each motor unit. The device is installed by the supplier of the motor and should never be removed from the motor.
The motor need never be commutated.
The commutation value of the motors is: 1.570800.
The motor, resolver and brakes are regarded as one complete unit, i.e. a replacement unit.
Product Manual IRB 2400 43
Motor units Repairs
44 Product Manual IRB 2400
Repairs Oil change in gearboxes
10 Oil change in gearboxes
10.1 Oil in gearboxes 1-3 (IRB 2400L/10/16)
ABB article no. 1171 2016-604 corresponds to:
BP: Energol GR-XP 320
Esso: Spartan EP 320
Optimol: Optigear BM 320
Texaco: Meropa 320
Castrol: Alpha SP 320
Klüber: Lamora 320
Shell: Omala Oil 320
Volume of gearbox 1:
Volume of gearboxes 2:
Volume of gearboxes 3:
6.4 litres (1.7 US gallon)
4.5 litres (1.3 US gallon)
3.8 litres (1.1 US gallon)
10.2 Oil in gearboxes 4-6 (IRB 2400/10/16)
ABB’s article no. 3HAC 0860-1 corresponds to:
Optimol: Optigear BM 100
Volume of gearbox 4:
Volume of gearboxes 5 and 6:
1.5 litres (0.4 US gallon)
0.8 litres (0.2 US gallon) total
10.3 Oil in gearboxes 4-6 (IRB 2400L)
ABB article no. 1171 2016-604 corresponds to:
BP:
Esso:
Energol GR-XP 320
Spartan EP 320
Optimol: Optigear 320
Texaco: Meropa 320
Volume of gearbox 4:
Castrol:
Klüber:
Shell:
Alpha SP 320
Lamora 320
Omala Oil 320
30 ml (0.008 US gallon)
Volume of wrist 120 ml (0.032 US gallon)
Product Manual IRB 2400 45
Oil change in gearboxes Repairs
10.4 Oil plugs, axes 4-6 (IRB 2400/10/16)
The magnetic oil plugs in gearboxes 4, 5 and 6 (see Figure 6) should be cleaned when filling
oil.
Oil plug axis 4
Oil plug axes 5 and 6
Figure 6 Location of oil plugs.
10.5 Oil plugs, axes 5-6 (IRB 2400L)
The magnetic oil plugs in gearboxes 5 and 6 (see Figure 7) should be cleaned when filling
oil.
Oil plug axes 5 and 6
Figure 7 Location of oil plugs.
10.6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16)
Drain the gearbox:
• Move the arms backwards, and the upper arm at least 45 o
upwards.
• The oil is drained through the lower drain plug hole at the rear of the upper arm.
New oil is refilled as follows:
• Run the upper arm in a vertical position (rear end upwards).
• The oil is filled through the plug hole.
46 Product Manual IRB 2400
Repairs Oil change in gearboxes
Oil level:
Floor and suspended mounting:
Volume:
- With the upper arm in a vertical position (rear end upwards) must the oil level be min. 32 mm and max. 25 mm from the edge of the upper hole.
• 1.5 litre (0.4 US gallon)
10.7 Changing and checking the oil in gearbox 4 (IRB 2400L)
Drain the gearbox:
• Dismantle the motor axis 4, see chapter 6, Changing the motor.
• Run the robot until the upper arm is pointing downward.
New oil is refilled as follows:
• Run the robot until the upper arm is pointing upward.
• The oil is filled through the motor hole.
Volume:
• 30 ml (0.008 US gallon).
10.8 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400/10/16)
Draining the gearbox:
• Run the upper arm to a horizontal position and turn axis 4 to the calibration position.
• Remove the oil plugs in the wrist (see Figure 6).
• Turn axis 4 through 90 o
so that the oil plug on the side of the wrist is pointing downwards.
• Then turn axis 4 another 90 o
.
• Let the remaining oil run out through the hole on the tilt housing (axis 5).
New oil is refilled as follows:
• Run the upper arm to a horizontal position and turn axis 4 to the calibration position.
• Fill oil in the hole located on the tilt housing (axis 5) until the oil reaches up to
the hole located on the side of the wrist (see Figure 6).
• NOTE! If the robot is mounted in suspension, the wrist should be turned 180 o
.
• Put the oil plugs back in the wrist.
Product Manual IRB 2400 47
Oil change in gearboxes
Oil level:
• Run the robot to the calibration position.
• The oil should be level with the edge of the oil hole on the side.
Volume: (IRB 2400/ 10/16)
• Oil volume for axes 5 and 6 is 0.8 litres (0.2 US gallon).
Repairs
10.9 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400L)
Draining the gearbox (IRB 2400L):
• Move the upper arm downwards. Both plugs must be off.
New oil is refilled as follows (IRB 2400L):
• Run the upper arm 30° upwards.
• The oil is filled through one of the op en front oil plugs.
• Do not fill oil through the rear two holes.
Volume (IRB 2400L):
• Oil volume for axes 5 and 6 is 0.12 litre (0.03 US gallon).
Oil level (IRB 2400L)
• Run the upper arm 30° upwards. Remove one of the oil plugs in the wrist (turn axis 6).
• The oil should be level with the edges of the oil hole.
48 Product Manual IRB 2400
Repairs Calibration
11 Calibration
11.1 General
The robot measurement system consists of one feedback unit for each axis and a measurement board which keeps track of the current robot position. The measurement board memory is battery-backed.
The measurement system needs to be carefully calibrated (as in 11.2) if any of the
resolver values change. Resolver values change when any
- part of the manipulator that affects the calibration position is replaced.
The system needs to be coarsely calibrated (as in 11.3) if the contents of the revolution
counter memory are lost. The memory may be lost if:
- the battery is discharged
- a resolver error occurs
- the signal between the resolver and measurement board is interrupted.
11.2 Adjustment procedure using calibration equipment (fine calibration)
The axes are calibrated in numerical order, i.e. 1 - 2 - 3 - 4 - 5 - 6.
1.
Move the robot to the calibration position, corresponding to the calibration marks,
2.
Calibrate all the axes as described below.
3.
Press the Misc. window key (see Figure 8).
P1
1
2
P2
P3
7 8 9
4 5 6
1 2
0
3
Figure 8 The Misc. window key.
4.
Choose Service from the dialog box that appears on the display.
Product Manual IRB 2400 49
Calibration
5.
Press Enter .
6.
Choose View: Calibration. The window shown in Figure 9 appears.
File Edit View
Service Calibration
Calib
Mech Unit Status
1(4)
Robot Not Calibrated
Repairs
50
Figure 9 The window shows whether or not the robot system units are calibrated.
The calibration status can be any of the following:
- Synchronized
All axes are calibrated and their positions are known. The unit is ready for use.
- Not updated Rev. Counter
All axes are fine-calibrated but the counter on one (or more) of the axes is
NOT updated. Therefore, this axis or axes must be updated as described in
- Not calibrated
One (or more) of the axes is NOT fine-calibrated. Therefore, this axis or axes
must be fine-calibrated as described in 11.2.
.
7.
If there is more than one unit, select the desired unit in the window in Figure 9.
Choose Calib: Calibrate and the window shown in Figure 10 will appear.
Calibration!
Robot
To calibrate, include axes and press OK.
X
X
X
X
Axis
1
2
3
4
5
6
Status
Not Fine Calibrated
Not Fine Calibrated
Fine Calibrated
Fine Calibrated
Not Fine Calibrated
Not Fine Calibrated
1(6)
Incl All Cancel OK
Figure 10 The dialog box used to calibrate the manipulator.
Product Manual IRB 2400
Repairs Calibration
8.
Press the function key All to select all axes, if all axes are to be calibrated.
Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).
9.
Confirm your choice by pressing OK. The window shown in Figure 11 appears.
Calibration!
Robot
- - - - - WARNING - - - - -
The calibration for all marked axes will be changed.
It cannot be undone.
OK to continue?
Cancel OK
Figure 11 The dialog box used to start the calibration.
10. Start the calibration by pressing OK.
An alert box is displayed during the calibration.
The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed.
The robot is now roughly calibrated.
11. Remove the protective plate from the reference surface on the manipulator base.
12. Attach the calibration tool for axis 1 on the guide pin underneath the gearbox, see
Guide pin
Figure 12 Calibration of axis 1.
Product Manual IRB 2400
Tool no.
3HAB 8064-1
51
Calibration Repairs
13. Release the brakes and move the manipulator manually and fix the tool to the base with the screw. NOTE! Do not tighten the screw.
14. Then move the manipulator so that the pin in the tool can be located in the guide hole in the base.
15. Update axis 1 only, as described above.
16. Remove the calibration tool for axis 1.
17. Fit the reference plane no. 6808 0011-GM on the foot.
Level sensors
0000
Reference plane
Calibrating sensors for axes 2, 3 and 5
52
Calibrating sensors for axes 4 and 6
Figure 13 Calibrating the sensors.
19. Fit the angle shelf no. 6808 0011-LP on the lower arm. Adjust the angle of the shelf, with the help of the sensors, before starting calibration.
20. Fit the angle shelf no. 6808 0011-GU + sync. adapter no. 3HAB 7981-1 + pin on the turning disc. Dont use synchronous adapter on IRB 2400L.
21. Position the sensors as shown Figure 14, for axis 2.
22. Run the manipulator so that the instrument shows 0 ±16 increments (0.4 mm/m).
23. Update axis 2 as described above. Remove the sensors.
24. Select the Program window and open the file CAL2410 on the Controller Parameter disk. Run the program and select Calib: Cal3. The robot will now move itself to the position for calibration of axis 3.
25. Put the sensors on the shelf and jog the robot to the calibration position,
0±16 increments. See Figure 14.
26. Update axis 3, as described above. Remove the sensors.
27. Run the calibration program 4A on the system diskette.
28. Calibrate the sensors for a new direction. See Figure 13.
Product Manual IRB 2400
Repairs Calibration
29. Run axis 4 to the correct position as indicated by the instrument, 0 ±32 increments.
30. Update axis 4 as described above. Remove the sensors.
31. Run the calibration program 4B.
32. The robot will now be standing in the correct position.
33. Update axis 4 as described above.
34. Calibrate the sensors for a new direction. See Figure 13.
35. Put the sensors on the shelf and run the robot so that axis 5 comes to the correct
calibration position, 0 ±32 increments. See Figure 14.
36. Update axis 5 as described above.
37. Calibrate the sensors for a new direction. See Figure 13.
38. Adjust axis 6, 0 ±32 increments. See Figure 14.
39. Update axis 6 as described above.
40. Save system parameters on a floppy disk.
Product Manual IRB 2400 53
Calibration Repairs
41. Change the values on the label, located underneath the flange plate on the base (see
Axis 2
View from above
Flange plate
Axis 4
Axis 3
Upper arm seen from above
Axis 6
54
Axes 4 and 6
Axis 5
Axes 2, 3 and 5
Figure 14 Calibration directions.
Calibration plate and calibration marks
42. The calibration positions for axes 1, 2, 3, 4 and 6 are marked using a punch mark
43. Check the calibration position as specified in 11.4.
Product Manual IRB 2400
Repairs Calibration
11.3 Setting the calibration marks on the manipulator
When starting up a new robot, a message may be displayed telling you that the manipulator is not synchronised. The message appears in the form of an error code on the teach pendant. If you receive such a message, the revolution counter of the manipulator
must be updated using the calibration marks on the manipulator. See Figure 19.
Examples of when the revolution counter must be updated:
- when the battery unit is discharged
- when there has been a resolver error
- when the signal between the resolver and the measuring system board has been interrupted
- when one of the manipulator axes has been manually moved without the controller being connected.
It takes 36 hours in Power On mode without any power interruption to recharge the battery unit.
If the resolver values must be calibrated, this should be done according to 11.2.
WARNING
Working in the robot work cell is dangerous.
Press the enabling device on the teach pendant and, using the joystick, manually move
the robot so that the calibration marks lie within the tolerance zone (see Figure 19).
N.B.! Axes 5 and 6 must be positioned together.
When all axes have been positioned as above, the values of the revolution counter can be stored by entering the following commands on the teach pendant:
1. Press the Misc. window key (see Figure 15).
P1
1
2
P2
P3
7 8 9
4 5 6
1 2
0
3
Figure 15 The Misc. window key from which the Service window can be chosen.
Product Manual IRB 2400 55
Calibration Repairs
2. Select Service in the dialog box shown on the display.
3. Press Enter .
4. Then, choose View: Calibration. The window shown in Figure 16 appears.
File Edit
Service Calibration
View
Mech Unit
Calib
Status
1(4)
Robot Unsynchronized
56
Figure 16 This window shows whether or not the robot system units are calibrated.
5. Select the desired unit in the window, as in Figure 16.
Choose Calib: Rev. Counter Update. The window shown in Figure 17 appears.
Rev. Counter Updating!
Robot
To update, include axes and press OK.
X
X
X
X
Axis
4
5
6
1
2
3
Status
Not updated Rev. Counter
Not updated Rev. Counter
Calibrated
Calibrated
Not updated Rev. Counter
Not updated Rev. Counter
1(6)
Incl All Cancel OK
Figure 17 The dialog box used to select the axes for which the revolution counter must be updated.
6. Press the function key All to select all axes, if all axes are to be updated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).
Product Manual IRB 2400
Repairs Calibration
7. Confirm by pressing OK. A window similar to the one in Figure 18 appears.
Rev. Counter Updating!
Robot
The Rev. Counter for all marked axes will be changed.
It cannot be undone.
OK to continue?
Cancel OK
Figure 18 The dialog box used to start updating the revolution counter.
8. Start the update by pressing OK.
If a revolution counter is incorrectly updated, it will cause incorrect positioning.
Thus, check the calibration very carefully after each update. Incorrect updating can damage the robot system or injure someone.
9. Check the calibration as described in 11.4.
10. Save system parametrs on a floppy disk.
Product Manual IRB 2400 57
Calibration
IRB 2400/10
IRB 2400/16
Repairs
Punch, axis 4
3HAB 8223-1
Punch, axis 6
3HAB 8184-1
Punch, axis 2
3HAB 8223-1
2 markings
Punch, axis 3
3HAB 8223-1
Punch, axis 1
3HAB 8223-1
IRB 2400L
Punch, axis 1
3HAB 8223-1
Punch, axis 1
3HAB 8184-1
Punch, axis 1
3HAB 8223-1
58
Punch, axis 1
3HAB 8223-1
Figure 19 Calibration marks on the manipulator.
Punch, axis 2
3HAB 8223-1
2 markings
Product Manual IRB 2400
Repairs Calibration
11.4 Checking the calibration position
There are two ways to check the calibration position; both are described below.
Using the diskette, Controller Parameters:
Run the program \ SERVICE \ CALIBRAT \ CAL 1400 (or 1400H) on the diskette, follow intructions displayed on the teach pendant. When the robot stops, switch to
MOTORS OFF. Check that the calibration marks for each axis are at the same level,
see Figure 19. If they are not, the setting of the revolution counters must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window and choose running axis-by-axis. Using the joystick, move the robot so that the read-out of the positions is equal to zero. Check that the cal-
ibration marks for each axis are at the same level, see Figure 19. If they are not, the
setting of the revolution counters must be repeated.
11.5 Alternative calibration positions
The robot must have been calibrated with calibration equipment at calibration position
0 for all axes (the robot is delivered with calibration position 0), see Figure 20, before
it can be calibrated in one of the alternative positions.
Axis
Calibration prog.
Cal pos
1
Normal
0
2
0
Normal
3
0
Axis
Calibration prog.
Cal pos
1
Normal
0
2 3
- 1.570796
Hanging
- 1.570796
Figure 20 Calibration positions
Product Manual IRB 2400 59
Calibration Repairs
Note!
If the final installation makes it impossible to reach the calibration 0 position, an alternative calibration position can be set before installation.
1. Run the calibration program CAL2410 on the Controller Parameter disk. Select
Cal.post Normal + Normal position, check the calibration marks for each axes.
2. Run the calibration program again and select the desired calibration position, see
3. Change to the new calibration offset for the axis in question, as follows:
• Select the window SERVICE;
• View: Calibration;
• Calib: Calibrate;
• Select axis
• Then confirm by pressing OK twice.
4. Change to the new calibration offset on the label, located under the cover on the back of the foot. The new calibration offset values can be found as follows:
• Select the window SYSTEM PARAMETERS;
• Manipulator
• Types: Motor;
• Select axis 1;
• Press Enter
• Note the Cal offset value.
5. Change to the new calibration position on the axes that have been changed, as follows:
• Select the window SYSTEM PARAMETERS;
• Topics: Manipulator;
• Types: Arm;
• Select axes;
• Change Cal pos to the value showed in Figure 20. The angle is in radians.
6. Restart the robot by selecting File: Restart.
7. Save the system parameters on a floppy disk
60 Product Manual IRB 2400
Repairs Calibration
11.6 Calibration equipment
For calibration:
Axis 1
Axis 2
Axis 3-6
3HAB 8064-1
6808 0011-LP
6808 0011-GU
3HAB 7981-1 (only 2400/10 and /16)
Reference
2111 2021-399
6808 0011-GM
Level indicator 6807 081-D
Marking equipment:
Axis 1-4
Axis 6
3HAB 8223-1
3HAB 8184-1
11.7 Operating the robot
How to start and operate the robot is described in the User’s Guide. Before start-up, make sure that the robot cannot collide with other objects in the working space.
Product Manual IRB 2400 61
Calibration Repairs
62 Product Manual IRB 2400
ABB Flexible Automation AB
T
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Key Features
- 6-axis industrial robot
- open structure
- flexible operation
- communication with external systems
- BaseWare OS operating system
- QuickMove motion control
- TrueMove path control
- multiple coordinate systems
- manual and automatic operation
- programming with teach pendant
