ABB IRB 640 M98 Robot Product Manual

Product Manual
IRB 640
3HAC 2950-1
M98
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 7677-1
Issue: M2000/Rev.1
ABB Robotics Products AB
S-721 68 Västerås
Sweden
Introduction
CONTENTS
Page
1 How to use this Manual........................................................................................... 3
2 What you must know before you use the Robot ................................................... 3
3 Identification ............................................................................................................ 4
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:
IRB 6400 M98
Robot version:
IRB 6400/2.4-150
Man. order:
See instructions
Serial. No:
6400-XXXX
Net weight
2,4.120 : 1870 kg
2,4-150 : 2010 kg
2,8-120 : 2010 kg
IRB 140(0)
IRB 640
XXXXXX
Nom. load
Date of manufacturing:
Identification plate showing
the IRB 6400
1997-XX-XX
3.0-75 : 2010 kg
S/2,9-120 : 2240 kg
PE/2,25-75 : 1590 kg
IRB 2400
IRB 6400
IRB 340
IRB 4400
IRB 840/A
Figure 1 Example of identification plate and it’s location on different manipulator types.
4
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.
64-00000
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 640
CONTENTS
Page
1 Introduction ..................................................................................................................... 3
2 Description ....................................................................................................................... 5
2.1 Structure.................................................................................................................. 5
2.2 Safety/Standards ..................................................................................................... 6
2.3 Operation ................................................................................................................ 7
2.4 Installation .............................................................................................................. 9
2.5 Programming .......................................................................................................... 9
2.6 Automatic Operation .............................................................................................. 12
2.7 Maintenance and Troubleshooting ......................................................................... 12
2.8 Robot Motion.......................................................................................................... 14
2.9 External Axes ......................................................................................................... 16
2.10 Inputs and Outputs................................................................................................ 17
2.11 Communication..................................................................................................... 18
3 Technical specification .................................................................................................... 19
3.1 Structure.................................................................................................................. 19
3.2 Safety/Standards ..................................................................................................... 21
3.3 Operation ................................................................................................................ 22
3.4 Installation .............................................................................................................. 23
3.5 Programming .......................................................................................................... 29
3.6 Automatic Operation .............................................................................................. 33
3.7 Maintenance and Troubleshooting ......................................................................... 33
3.8 Robot Motion.......................................................................................................... 34
3.9 External Axes ......................................................................................................... 36
3.10 Inputs and Outputs................................................................................................ 37
3.11 Communication..................................................................................................... 41
4 Specification of Variants and Options........................................................................... 43
5 Accessories ....................................................................................................................... 57
6 Index ................................................................................................................................. 59
Product Specification IRB 640 M98/BaseWare OS 3.1
1
Product Specification IRB 640
2
Product Specification IRB 640 M98/BaseWare OS 3.1
Introduction
1 Introduction
Thank you for your interest in the IRB 640. This manual will give you an overview of
the characteristics and performance of the robot.
IRB 640 is a 4-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 IRB 640 is extremely powerful with a handling capacity of 160 kg, and thanks to
optimised robot drive-trains and ABB’s patented QuickMoveTM functions, it is the
quickest robot in its class.
Extra equipment, such as transformers and valve packages, can be placed on the upper
arm or on the frame of axis 1 (see Chapter 3.4).
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 - palletizing, communication features - network
communication - and advanced functions - multitasking, sensor control etc. For a
complete description of 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.
Accessories, such as track motion, base plates, motors for external axes, and tool
systems with tool exchangers, have been specially adapted for use with the IRB 640
(see Chapter 5).
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 chapters 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.
Product Specification IRB 640 M98/BaseWare OS 3.1
3
Introduction
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 640 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 3
Axis 2
Axis 6
Axis 1
Figure 1 The IRB 640 manipulator has 4 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 640 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 a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
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Product Specification IRB 640 M98/BaseWare OS 3.1
Description
Restricting the working space
The movement of each axis can be restricted using software limits. Axes 1-3 can also
be restricted by means of mechanical stops.
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp
As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the 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
1
2
P1
7
8
9
4
5
6
1
2
3
Joystick
0
P2
P3
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 operations can be carried out from the teach pendant,
which means that an additional keyboard is not required. All information, including the
complete programming language, is in English or, if preferred, some other major
language. (For a list of languages, see Product Specification RobotWare.)
Product Specification IRB 640 M98/BaseWare OS 3.1
7
Description
Menu keys
File
Edit
View
1 Goto ...
Inputs/Outputs
2 Goto Top
3 Goto Bottom
Value
Name
1
0
1
0
1
1
13
di1
di2
grip1
grip2
clamp3B
feeder
progno
I/O list
1
Menu
4(6)
Line indicator
Cursor
0
Function keys
Figure 4 Window for manual operation of input and output signals.
Using the joystick, the robot can be manually jogged (moved). The user determines the
speed of this movement; large deflections of the joystick will move the robot quickly,
smaller deflections will move it more slowly.
The robot supports different user tasks, with dedicated windows for:
- Production
- Programming
- System setup
- Service and installation
Operator’s panel
Motors On button
Operating mode selector
and indicating lamp
Emergency stop
Duty time counter
Figure 5 The operating mode is selected using the operator’s panel on the controller.
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Product Specification IRB 640 M98/BaseWare OS 3.1
Description
Using a key switch, the robot can be locked in two or three different operating modes
depending on chosen mode selector:
100%
• Automatic mode:
Running production
• Manual mode at reduced speed:
Programming and setup
Max. speed: 250 mm/s (600 inches/min.)
• 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 IRB 640 is designed for floor mounting. An end effector of max. weight 160 kg,
including payload, can be mounted on the mounting flange (axis 6). Load diagram, see
chapter 3.4.
Extra loads (valve packages) can be mounted on the upper arm. An extra load can also
be mounted on the frame of axis 1. Holes for extra equipment are described in
chapter 3.4.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axis 1 and axis 2 for position indication of the manipulator.
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.
Product Specification IRB 640 M98/BaseWare OS 3.1
9
Description
Programs, parts of programs and any modifications can be tested immediately without
having to translate (compile) the program.
The program is stored as a normal PC text file, which means that it can be edited using
a standard PC.
Movements
A sequence of movements is programmed as a number of partial movements between
the positions to which you want the robot to move.
The end position of a movement is selected either by manually jogging the robot to the
desired position with the joystick, or by referring to a previously defined position.
The exact position can be defined (see Figure 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 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
provides fast memory for program storage. These can then be automatically
downloaded using a program instruction. The complete program or parts of programs
can be transferred to/from 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 later.
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Product Specification IRB 640 M98/BaseWare OS 3.1
Description
Editing programs
Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy,
delete, find and change, undo etc. Individual arguments in an instruction can also be
edited using these commands.
No reprogramming is necessary when processing left-hand and right-hand parts, since
the program can be mirrored in any plane.
A robot position can easily be changed either by
- jogging the robot with the joystick to a new position and then pressing the
“ModPos” key (this registers the new position)
or by
- entering or modifying numeric values.
To prevent unauthorised personnel from making program changes, passwords can be
used.
Testing programs
Several helpful functions can be used when testing programs. For example, it is
possible to
- start from any instruction
- execute an incomplete program
- run a single cycle
- execute forward/backward step-by-step
- simulate wait conditions
- temporarily reduce the speed
- change a position
- tune (displace) a position during program execution.
For more information, see the User’s Guide and RAPID Reference Manual.
Product Specification IRB 640 M98/BaseWare OS 3.1
11
Description
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:
FrontA
FrontB
FrontC
Other
SERVICE
Figure 7 The operator dialogs can be easily customised.
A special input can be set to order the robot to go to a service position. After service,
the robot is ordered to return to the programmed path and continue program execution.
You can also create special routines that will be automatically executed when the power
is switched on, at program start and on other occasions. This allows you to customise
each installation and to make sure that the robot is started up in a controlled way.
The robot is equipped with absolute measurement, making it possible to operate the
robot directly when the power is switched on. For your convenience, the robot saves
the used path, program data and configuration parameters so that the program can be
easily restarted from where you left off. Digital outputs are also set automatically to the
value prior to the power failure.
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:
- The controller is enclosed, which means that the electronic circuitry is protected
when operating in a normal workshop environment.
- Maintenance-free AC motors are used.
- Liquid grease or 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.
- It has a program memory “battery low” alarm.
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Product Specification IRB 640 M98/BaseWare OS 3.1
Description
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 a 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 teach pendant display, stored in a file or printed on a printer.
- There are commands and service programs in RAPID to test units and functions.
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.
Product Specification IRB 640 M98/BaseWare OS 3.1
13
Description
2.8 Robot Motion
-3
2/3 +3
-2
+2
-6
+6
TCP 0
2310
-1
+1
599
1220
2905
Figure 8 Working space of IRB 640 (TCP 0, dimensions in mm).
Motion performance
The QuickMoveTM concept means that a self-optimizing motion control is used.
The robot automatically optimizes the servo parameters to achieve the best possible
performance throughout the cycle - based on load properties, location in working area,
velocity and direction of movement.
- No parameters have to be adjusted to achieve correct path, orientation and
velocity.
- Maximum acceleration is always obtained (acceleration can be reduced, e.g.
when handling fragile parts).
- The number of adjustments that have to be made to achieve the shortest possible
cycle time is minimized.
The TrueMoveTM concept means that the programmed path is followed – regardless of
the speed or operating mode – even after an emergency stop, a safeguarded stop, a
process stop, a program stop or a power failure.
The robot can, in a controlled way, pass through singular points, i.e. points where two
axes coincide.
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Product Specification IRB 640 M98/BaseWare OS 3.1
Description
Coordinate systems
Y
X
Tool coordinates
Z
Z
Z
Tool Centre Point (TCP)
Y
Base coordinates
X
Z
Z
Z User
coordinates
Object
coordinates
Y
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.
The base coordinate system is attached to the base mounting surface of the robot.
The tool coordinate system specifies the tool’s centre point and orientation.
The user coordinate system specifies the position of a fixture or workpiece
manipulator.
The object coordinate system specifies how a workpiece is positioned in a fixture or
workpiece manipulator.
The coordinate systems can be programmed by specifying numeric values or jogging
the robot through a number of positions (the tool does not have to be removed).
Each position is specified in object coordinates with respect to the tool’s position and
orientation. This means that even if a tool is changed because it is damaged, the old
program can still be used, unchanged, by making a new definition of the tool.
If a fixture or workpiece is moved, only the user or object coordinate system has to be
redefined.
Product Specification IRB 640 M98/BaseWare OS 3.1
15
Description
Stationary TCP
When the robot is holding a work object and working on a stationary tool, it is possible
to define a TCP for that tool. When that tool is active, the programmed path and speed
are related to the work object.
Program execution
The robot can move in any of the following ways:
- Joint motion (all axes move individually and reach
the programmed position at the same time)
- Linear motion (the TCP moves in a linear path)
- Circle motion (the TCP moves in a circular path)
Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection
in processed objects can occur.
If the location of a workpiece varies from time to time, the robot can find its position
by means of a digital sensor. The robot program can then be modified in order to adjust
the motion to the location of the part.
Jogging
The robot can be manually operated in any one of the following ways:
- Axis-by-axis, i.e. one axis at a time
- Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate
systems mentioned above)
- Reoriented around the TCP
It is possible to select the step size for incremental jogging. Incremental jogging can be
used to position the robot with high precision, since the robot moves a short distance
each time the joystick is moved.
During manual operation, the current position of the robot and the external axes can be
displayed on the teach pendant.
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 for example, a one-axis
linear robot carrier and a rotational external axis.
16
Product Specification IRB 640 M98/BaseWare OS 3.1
Description
A mechanical unit can be activated or deactivated to make it safe when, for example,
manually changing a workpiece located on the unit. In order to reduce investment
costs, any axes that do not have to be active at the same time, can share the same drive
unit.
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.
The inputs and outputs can be configured to suit your installation:
- Each signal and unit can be given a name, e.g. gripper, feeder.
- I/O mapping (i.e. a physical connection for each signal).
- Polarity (active high or low).
- Cross connections.
- Up to 16 digital signals can be grouped together and used as if they were a single signal when, for example, entering a bar code.
Signals can be assigned to special system functions, such as program start, so as to be
able to control the robot from an external panel or PLC.
The robot can work as a PLC by monitoring and controlling I/O signals:
- I/O instructions can be executed concurrent to the robot motion.
- Inputs can be connected to trap routines. (When such an input is set, the
trap routine starts executing. Following this, normal program execution
resumes. In most cases, this will not have any visible effect on the robot motion,
i.e. if a limited number of instructions are executed in the trap routine.)
- Background programs (for monitoring signals, for example) can be
run in parallel with the actual robot program. Requires Multitasking option, see
Product Specification RobotWare.
Product Specification IRB 640 M98/BaseWare OS 3.1
17
Description
Manual functions are available to:
- List all the signal values.
- Create your own list of your most important signals.
- Manually change the status of an output signal.
- Print signal information on a printer.
I/O signals can also be routed to connectors on the upper arm of the robot.
2.11 Communication
The robot can communicate with computers or other equipment via RS232/RS422
serial channels or via Ethernet. However this requires optional software, see Product
Specification RobotWare.
18
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
3 Technical specification
3.1 Structure
Weight: Manipulator 1950 kg
Controller
240 kg
Volume: Controller
950 x 800 x 540 mm
Airborne noise level:
The sound pressure level outside
the working space
< 70 dB (A) Leq (acc. to
Machinery directive 89/392 EEC)
50
800
540
Cabinet extension
Option 115
800
Extended cover
Option 114
500
250
200
950
980 *
Lifting points
for forklift
* Castor wheels
500
Figure 10 View of the controller from the front, from above and from the side (dimensions in mm).
Product Specification IRB 640 M98/BaseWare OS 3.1
19
Technical specification
1954
1840
692
900
1235
950
400
1277
1049
188
922
1044
R 715
304
Figure 11 View of the manipulator from the side, rear and above (dimensions in mm).
20
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
3.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1992
Industrial robots, safety requirements
ISO 9409-1
Manipulating industrial robots, mechanical interface
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 50082-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) 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 12).
Operating mode selector
Auto mode
safeguarded space stop
General mode
safeguarded space stop
External emergency stop
Emergency stop
<250 mm/s
100%
Teach pendant
Enabling device
M
~
Note! Manual mode 100% is an option
Figure 12 All safeguarded space stops force the robot’s motors to the MOTORS OFF state.
A time delay can be used on the emergency stops or any safeguarded space stops.
Product Specification IRB 640 M98/BaseWare OS 3.1
21
Technical specification
3.3 Operation
Hold-to-run
Menu keys
Motion keys
P5
P4
7
4
1
Window
keys
1
2
Display
P1
8
5
2
0
9
6
3
Joystick
Enabling
device
P2
P3
Function keys
Navigation keys
Figure 13 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 when jogging.
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:
- Jog (manual operation)
- Program, edit and test a program
- Manual input/output management
- File management
- System configuration
- Service and troubleshooting
- Automatic operation
22
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
User-defined keys (P1-P5)
Five user-defined keys that can be configured to set or reset an output (e.g. open/close
gripper) or to activate a system input (see chapter 3.10).
3.4 Installation
Operating requirements
Protection standards
IEC529
Manipulator
Wrist
Controller
IP54
IP55
IP54
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator and controller during operation
+5oC (41oF) to +45oC (113oF)
Complete robot during transportation and storage -25oC (13oF) to +55oC (131oF)
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%
Mains frequency
48.5 to 61.8 Hz
Rated power
8.3 kVA - 15.5 kVA
Absolute measurement backup
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
Language
Date and time
Power on sequence
EM stop sequence
Password protection for configuration and program
window
User-defined lists of I/O signals
User-defined set of instructions
User-defined instructions
Customised operator dialogs
All text on the teach pendant can be displayed in several
languages
Calendar support
Action taken when the power is switched on
Action taken at an emergency stop
Product Specification IRB 640 M98/BaseWare OS 3.1
23
Technical specification
Main start sequence
Action taken when the program is
starting from the beginning
Program start sequence
Action taken at program start
Program stop sequence
Action taken at program stop
Change program sequence Action taken when a new program is loaded
Working space
Working space limitations
External axes
Number, type, common drive unit, mechanical units
Brake delay time
Time before brakes are engaged
I/O signal
Logical names of boards and signals, I/O mapping,
cross connections, polarity, scaling, default value at
start up, interrupts, group I/O
Serial communication
Configuration
For a detailed description of the installations procedure, see the Product Manual Installation and Commissioning.
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load
in operation
Force xy
Force z
Max. load at
emergency stop
± 12000 N
21000 ± 5500 N
± 18000 N
21000 ± 10000 N
± 32000 Nm
± 6000 Nm
± 39000 Nm
± 13000 Nm
Torque xy
Torque z
Y
∅ 0.2 (3x)
D=48 (3x)
D=32 (3x)
415.7
720
100 ±0,5
Z
X
D=64 H9 (3x)
A
15
+2
0
A
Support surface D=85 (3x)
480 ±0.1
A-A
Figure 14 Hole configuration (dimensions in mm).
24
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
Load diagram for IRB 640, up to 160 kg
0.1
0.2
0.3
0.4
L (m)
0.1
0.2
0.3
160 kg
0.4
150 kg
0.5
125 kg
100 kg
0.6
75 kg
0.7
Z (m)
Mass inertia can be set to anything and will
affect the acceleration/deceleration of the robot
The load diagram is valid for J 0 <100 kgm2.
J0 = the maximum component (J X0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 15 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
Product Specification IRB 640 M98/BaseWare OS 3.1
25
Technical specification
Mounting equipment
Extra loads can be mounted on the upper arm and the frame. Definitions of distances
and masses are shown in Figure 16 (upper arm) and in Figure 17 (frame).
The robot is supplied with holes for mounting extra equipment (see Figure 18).
Upper arm
Permitted extra load on upper arm plus the maximum handling weight
(See Figure 16):
M1 ≤ 35 kg with distance a ≤ 500 mm, centre of gravity in axis 3 extension
or
M2 ≤ 35 kg with distance b ≤ 400 mm
If the handling weight is lower than the maximum weight, the upper arm
load can be increased.
For example, if the handling weight is only 120 kg, which is 40 kg less than
max. handling capacity, you can put additional 40 kg on top of M1 or M2
on the upper arm. These “additional 40 kg” can be mounted in any of the
holes for extra equipment.
The upper arm load should then be defined in the software as one mass.
It is important that this is done correctly to ensure that the robot’s motions
remain perfect.
For more information, see User’s Guide - System Parameters.
M2
M1
M1
b
a
Mass
centre
Holes for extra equipment
Measurement see Figure 18
Figure 16 Permitted extra load on upper arm.
26
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
Frame (Hip Load)
Permitted extra load on frame is JH = 120 kgm2.
Recommended position (see Figure 17).
JH = JH0 + M4 • R2
is the moment of inertia of the equipment
where
JH0
R
is the radius (m) from the centre of axis 1
M4
is the total mass (kg) of the equipment including
bracket and harness (≤ 320 kg)
362
M4
JH0
R around
axis 1
Note!
Hip load can only be mounted on the robot’s left side.
Forklift device on the right side must be dismounted before using the robot.
Figure 17 Extra load on frame of IRB 640 (dimensions in mm).
260
126
99
200
M10 (4x) through
130
230
Limit for M10 surfaces
45
M10 (2x)
depth 25
M10 (2x) through
35 100
80
Limit for M10 surfaces
60 69
220
411
486
Figure 18 Holes for mounting extra equipment (dimensions in mm).
Product Specification IRB 640 M98/BaseWare OS 3.1
27
Technical specification
30o
D=10 H7 depth 10
8
M10 (6x) depth 18
D=80 H7
D=160 h7
60o
D=125
F-F
8
Figure 19 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm).
28
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
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 lists 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
Calls a new procedure
CallByVar
Calls a procedure by a variable
RETURN
Finishes execution of a routine
FOR
Repeats a given number of times
GOTO
Goes to (jumps to) a new instruction
Compact IF
IF a condition is met, THEN execute one instruction
IF
IF a condition is met, THEN execute a sequence of instructions
label
Line name (used together with GOTO)
TEST
Depending on the value of an expression ...
WHILE
Repeats as long as ...
Product Specification IRB 640 M98/BaseWare OS 3.1
29
Technical specification
Stop
EXIT
Break
Stops execution
Stops execution when a restart is not allowed
Stops execution temporarily
Motion settings
AccSet
ConfJ
ConfL
VelSet
GripLoad
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
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
Motion
MoveC
MoveJ
MoveL
MoveAbsJ
MoveXDO
SearchC
SearchL
ActUnit
DeactUnit
Offs
RelTool
MirPos
CRobT
CJointT
CPos
CTool
CWObj
StopMove
StartMove
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
Inverts the value of a digital output signal
PulseDO
Generates a pulse on a digital output signal
Reset
Sets a digital output signal to 0
Set
Sets a digital output signal to 1
SetAO
Sets the value of an analog output signal
SetDO
Sets the value of a digital output signal after a defined time
SetGO
Sets the value of a group of digital output signals
WaitDI
Waits until a digital input is set
WaitDO
Waits until a digital output is set
AInput
Reads the value of an analog input signal
DInput
Reads the value of a digital input signal
DOutput
Reads the value of a digital output signal
30
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
GInput
GOutput
TestDI
IODisable
IOEnable
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
Interrupts
ISignalDI
ISignalDO
ITimer
IDelete
ISleep
IWatch
IDisable
IEnable
CONNECT
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
Error Recovery
EXIT
RAISE
RETRY
TRYNEXT
RETURN
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
Communication
TPErase
TPWrite
TPReadFK
TPReadNum
ErrWrite
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
System & Time
ClkReset
ClkStart
ClkStop
ClkRead
CDate
CTime
GetTime
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
Mathematics
Add
Clear
Decr
Incr
Abs
Sqrt
Exp
Pow
ACos
ASin
ATan/ATan2
Cos
Sin
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 640 M98/BaseWare OS 3.1
31
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 MB2)
6.0 MB2)
Instructions1)
7500
18000
Mass storage3):
RAM memory Standard
0.5 MB
3000
Extended 8 MB 4 MB
31000
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.
32
Product Specification IRB 640 M98/BaseWare OS 3.1
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.
- Changing grease and oil every third year.
- Changing batteries every third year.
- Some additional checks every year.
The maintenance intervals depends on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.
Product Specification IRB 640 M98/BaseWare OS 3.1
33
Technical specification
3.8 Robot Motion
IRB 640
Type of motion
Range of movement
Axis 1
Axis 2
Axis 3
Axis 6
+180o
+70o
+85o
+300o
Rotation motion
Arm motion
Arm motion
Turn motion
Z
to -180o
to -70o
to -28o
to -300o
-3
Pos 6
-2
Pos 1
+3
+6
-6
+2
2310
2/3
TCP 0
Pos 2
Pos 5
+1
599
-1
X
Pos 3
Pos 4
1220
2905
Positions at TCP 0 (mm)
Pos
0
1
2
3
4
5
6
X
Z
2028
999
1139
761
1328
2905
2464
1536
1685
1053
-31
-599
770
2119
Angle 2/3 (ϕ2/ϕ3)
Min. 25o Max. 155o
90o at pos. 0
pos. axis 2 axis 3
(ϕ2) (ϕ3)
0
1
2
3
4
5
6
0o
-70o
-70o
40o
70o
70o
37o
0o
-28o
-5o
85o
85o
5o
-28o
Figure 20 The extreme positions of the robot arm
34
Product Specification IRB 640 M98/BaseWare OS 3.1
Technical specification
Velocity
Axis no. 1
2
3
6
125o/s
125o/s
125o/s
275o/s
There is a supervision function to prevent overheating in applications with intensive
and frequent movements.
Resolution
Approx. 0.01o on each axis.
Product Specification IRB 640 M98/BaseWare OS 3.1
35
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 according to Figure 21. See
Specification of Variants and Options for more information.
Resolver
Connected directly to motor shaft
Transmitter type resolver
Voltage ratio 2:1 (rotor: stator)
Resolver supply
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 21, or inside the cabinet.
For more information on how to install an external axis, see the Product Manual Installation and Commissioning.
Alternatively, it is possible to communicate with external drive units from other
vendors. See Product Specification RobotWare.
SMB
Not supplied on delivery
Alt.
SMB
Not supplied on delivery
Figure 21 Outline diagram, external axes.
36
Product Specification IRB 640 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.
Digital
Type of unit
Analog
Option no.
In
Out
Digital I/O 24 VDC
20x
16
16
Internal/External1
Digital I/O 120 VAC
25x
16
16
Internal/External
Analog I/O
22x
AD Combi I/O
23x
16
16
Relay I/O
26x
16
16
Allen-Bradley
Remote I/O Slave
281
1282
128
Interbus-S Slave
284-285
642
64
Profibus DP Slave
286-287
1282
128
100
100
Simulated I/O3
Encoder interface
unit4
288-289
Voltage
inputs
4
Voltage
output
3
2
Current
output
1
Power supply
Internal
Internal/External1
Internal/External1
30
30
1
1. The digital signals are supplied in groups, each group having 8 inputs or outputs.
2. To calculate the number of logical signals, add 2 status signals for RIO unit and 1 for Interbus-S
and Profibus DP.
3. A non physical I/O unit can be used to form cross connections and logical conditions without
physical wiring. No. of signals are to be configured. Some ProcessWares include SIM unit.
4. Dedicated for conveyor tracking only.
Distributed I/O
The total number of logical signals is 512 (inputs or outputs, group I/O, analog and
digital including field buses)
Max. total no of units*
Max. total cable length
Cable type (not included)
Data rate (fixed)
20 (including SIM units)
100 m
According to DeviceNet specification release 1.2
500 Kbit/s
* Max. four units can be mounted inside the cabinet.
Product Specification IRB 640 M98/BaseWare OS 3.1
37
Technical specification
Signal data
Permitted customer 24 V DC load
Digital inputs
24 V DC
max. 6 A
(options 20x/23x/26x)
Optically-isolated
Rated voltage:
24 V DC
Logical voltage levels: “1”
15 to 35 V
“0”
-35 to 5 V
Input current at rated input voltage:
6 mA
Potential difference:
max. 500 V
Time delays:
hardware
5−15 ms
software
≤ 3 ms
Time variations:
± 2 ms
Digital outputs (options 20x/23x)
24 V DC
Optically-isolated, short-circuit protected, supply polarity protection
Voltage supply
19 to 35 V
Rated voltage
24 V DC
Output current:
max. 0.5 A
Potential difference:
max. 500 V
Time delays:
hardware
≤ 1 ms
software
≤ 2 ms
Time variations:
± 2 ms
Relay outputs
Digital inputs
120 V AC
38
(options 26x)
Single pole relays with one make contact (normally open)
Rated voltage:
24 V DC, 120 VAC
Voltage range:
19 to 35 V DC
24 to 140 V AC
Output current:
max. 2 A
Potential difference:
max. 500V
Time intervals: hardware (set signal)
typical 13 ms
hardware (reset signal) typical 8 ms
software
≤ 4 ms
(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
Product Specification IRB 640 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:
24 to 140 V AC
Potential difference:
max. 500 V
Off state leakage current:
max. 2mA rms
On state voltage drop:
max. 1.5 V
Time intervals: hardware
≤ 12 ms
software
≤ 4 ms
Analog inputs (options 22x)
Voltage Input voltage:
Input impedance:
Resolution:
Accuracy:
Analog outputs (option 22x)
Voltage Output voltage:
Load impedance:
Resolution:
Current Output current:
Load impedance:
Resolution:
Accuracy:
+10 V
>1 Mohm
0.61 mV (14 bits)
+0.2% of input signal
min.
min.
+10 V
2 kohm
2.44 mV (12 bits)
4-20 mA
800 ohm
4.88 µA (12 bits)
+0.2% of output signal
Analog outputs (option 23x)
Output voltage (galvanically isolated):
Load impedance:
min.
Resolution:
Accuracy:
Potential difference:
Time intervals: hardware
software
Product Specification IRB 640 M98/BaseWare OS 3.1
0 to +10 V
2 kohm
2.44 mV (12 bits)
±25 mV ±0.5% of output
voltage
max. 500 V
≤ 2.0 ms
≤ 4 ms
39
Technical specification
Signal connections on robot arm
Signals
Power
Air
23
10
1
50 V, 250 mA
250 V, 2 A
Max. 10 bar, inner hose diameter 11 mm
CAN bus (option 04z)
Signals
12
Power
5
Air
1
50 V, 250 mA
250 V, 2 A
Max. 10 bar, inner hose diameter 11 mm
Customer Power Vacuum (option 046)
Power
Protective earth
6
2
400 V, 4 A
System signals
Signals can be assigned to special system functions. Several signals can be given the
same functionality.
Digital outputs
Motors on/off
Executes program
Error
Automatic mode
Emergency stop
Restart not possible
Run chain closed
Digital inputs
Motors on/off
Starts program from where it is
Motors on and program start
Starts program from the beginning
Stops program
Stops program when the program cycle is ready
Stops program after current instruction
Executes “trap routine” without affecting status of stopped
regular program1
Loads and starts program from the beginning1
Resets error
Resets emergency stop
System reset
Analog output
TCP speed signal
1. Program can be decided when configuring the robot.
For more information on system signals, see User’s Guide - System Parameters.
40
Product Specification IRB 640 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 22).
Figure 22 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 23).Transmission rate is 10 Mbit/s.
Figure 23 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 of the options FactoryWare Interface or RAP Communication, see
Product Specification RobotWare.
Product Specification IRB 640 M98/BaseWare OS 3.1
41
Technical specification
42
Product Specification IRB 640 M98/BaseWare OS 3.1
Specification of Variants and Options
4 Specification of Variants and Options
The different variants and options for the IRB 640 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 VERSION
021 IRB 640
040 APPLICATION INTERFACE
Air supply and signals for extra equipment to upper arm
04y Integrated hose for compressed air. There is an inlet at the base (see Figure 24) and an
outlet on the tilthouse (see Figure 25). Connections: R1/2”.
For connection of extra equipment on the manipulator, there are cables integrated into
the manipulator’s cabling and two connectors:
- one Burndy 23-pin UTG 018-23S
- one Burndy 12-pin UTG 014-12S
04z Integrated hose for compressed air. There is an inlet at the base (see Figure 24) and an
outlet on the tilthouse (see Figure 25). Connections: R1/2”.
For connection of extra equipment on the manipulator there is a CAN cable (length
from the hole on the upper arm: 645 mm) integrated into the manipulator’s cabling. The
connectors are:
- one Burndy 23-pin (12 available) UTG 018-23S
- one Burndy 12-pin (5 available) UTG 014-12S
- one CAN DeviceNet 5-pole female connector (Ø 1”)
One of the following alternative options, 045 or 67x, must be selected.
045 The signals are connected directly to the manipulator base to one Harting 40-pin
connector (see Figure 24). The cables from the manipulator base are not supplied.
67x The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08,
in the controller (see Figure 31).
The cable between R1.CP/CS and the controller is supplied. The cable length is the
same as in option 640.
046 Customer Power Vacuum
Cabling from the manipulator’s base to the left side of the frame (for connection
with a vacuum pump, see Figure 24).
On the base one Burndy 23 pin UTG 018-23S. On the left side of the manipulator’s
frame the cable ends with six wires + two protective earth.
Product Specification IRB 640 M98/BaseWare OS 3.1
43
Specification of Variants and Options
Option 046
R1.CPV
Air R1/2”
Option 045
Option 046
R1.CP/CS
R1.CPV
CAN Bus connection (04z)
R1.CB
Figure 24 Connections at the manipulator base.
CAN Bus connection (04z)
CP/CS
(04y, 04z)
Figure 25 Connection of signals on the upper arm.
060 LIFTING DEVICE
061 Lifting device on the manipulator for fork-lift handling is not mounted at delivery.
Lifting eyes for use with an overhead crane are integrated as standard.
44
Product Specification IRB 640 M98/BaseWare OS 3.1
Specification of Variants and Options
070 POSITION SWITCH
Position switches indicating the position of one or two of the main axes. Rails with
separate adjustable cams are attached to the manipulator. The cams, which have to be
adapted to the switch function by the user, can be mounted in any position in the
working range for each switch.
The position switch device is delivered as a kit to be assembled when installing the
robot. Assembly instruction is included.
Note! This option may require external safety arrangements, e.g. light curtains,
photocells or contact mats.
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 (see Figure 31). The cable is between the manipulator base R1.SW (see
Figure 26) and the controller is included. The cable lengths are the same as in
option 640.
1, 2 or 3 switches indicating the position of axis 1.
Switch type: Telemecanique XCK-M1/ZCK-D16, 2 pole N/C + N/O, according to
IEC 947-5-1.
081
082
083
084
1 switch, axis 1
2 switches, axis 1
3 switches, axis 1
1 switch, axis 2
R1.SW
Air R1/2”
Figure 26 Connection of position switch cable to the base.
085 MANIPULATOR COLOUR
It is possible to choose either orange or white coloured manipulator with different labels.
08d Consumer goods white manipulator, red ABB and FlexPalletizer labels
08e Orange manipulator, black ABB and FlexPalletizer labels
08f
Orange standard manipulator
Product Specification IRB 640 M98/BaseWare OS 3.1
45
Specification of Variants and Options
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.
114 With extended cover 250 mm.
The heigth 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
inside. (See Figure 27).
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 27 Mounting plate for mounting of equipment (dimensions in mm).
120 CABINET TYPE
121 Standard, i.e. without Castor wheels.
122 Cabinet on Castor wheels.
46
Product Specification IRB 640 M98/BaseWare OS 3.1
Specification of Variants and Options
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 28).
Figure 28 CEE male connector.
134 Connection via an industrial Harting 6HSB connector in
accordance with DIN 41640.
35 A, 600 V, 6p + PE (see Figure 29).
136* 32 A, 380-415 V, 3p + N + PE (see Figure 28).
Figure 29 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.
151-174
Voltage
200 V
220 V
400 V
440 V
Voltage
400 V
440 V
475 V
500 V
Voltage
475 V
500 V
525 V
600 V
Product Specification IRB 640 M98/BaseWare OS 3.1
47
Specification of Variants and Options
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
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.
M4 (x4)
M8 (x4)
45o
196
Required depth 200 mm
193
180 224 240
223
70
62
140
96
Holes for
flange
184
External panel enclosure
(not supplied)
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
200
Holes for
operator’s panel
90
5 (x2)
155
Figure 30 Required preparation of external panel enclosure (all dimensions in mm).
48
Product Specification IRB 640 M98/BaseWare OS 3.1
Specification of Variants and Options
183 External, mounted in a box,
(see figure on the right).
M5 (x4) for fastening of box
Cable length
185 15 m
186 22 m
187 30 m
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 UNITS MOUNTED IN CABINET
The standard cabinet can be equipped with up to four I/O units. For more details, see
Technical Specification 3.10.
X1 (SIO1)
Backplane
X2 (SIO2)
I/O units (x4)
X10 (CAN3)
X16 (CAN2)
XT5, customer signals, option 67x
XT6, customer power, option 67x
XT8, position switch, option 07x
XT31 (24V supply) and service outlet
Figure 31 I/O unit and screw terminal locations.
Product Specification IRB 640 M98/BaseWare OS 3.1
49
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 31). 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 MOUNTED IN CABINET
For more details, see Technical Specification 3.10.
281 Allen Bradley Remote I/O
Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC
equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the number of
I/O units that can be mounted in cabinet by one. The field bus cables are connected
directly to the A-B RIO unit in the upper part of the cabinet (see Figure 31). 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. 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 the function whereby the robot follows a work
object which is mounted on a moving conveyor. The encoder and synchronization
switch cables are connected directly to the encoder unit in the upper part of the cabinet
(see Figure 31). Screw connector is included. For more information see Product
Specification RobotWare.
50
Product Specification IRB 640 M98/BaseWare OS 3.1
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-ST5.08) are not included. See Figure 22 and Figure 31.
292 Ethernet (see Figure 23). 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.)
392 Drive unit GT
A separate drive unit including two drives. Recommended motor types see Figure 32.
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 axis 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 type see Figure 32.
37P-Q
Drive unit ECB, for 3 or 6 motors. Recommended motor type see
Figure 32.
Product Specification IRB 640 M98/BaseWare OS 3.1
51
Specification of Variants and Options
Max current
Rated current
Motor type1
G
6 - 30A rms
16A rms
S, M, L
T
7,5 - 37A rms
20A rms
S, M, L
E
5,5 - 27Arms
8,4Arms
S, M
C
2,5 - 11A rms
5A rms
S
B
1,5 - 7A rms
4A rms
S
Drive unit data
1. Motors from Flexible Automation/System Products.
Types: S=small, M=medium, L=large
Figure 32 Motor selecting table.
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, 4 A or 230 V, 2A.
Note! Connection before mains switch is not in compliance with some national
standards, NFPL 79 for example.
52
Product Specification IRB 640 M98/BaseWare OS 3.1
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 31). Voltage range: 110 - 240 V AC.
470 DISK DRIVE COOLING
The disk drive normally works well at temperatures up to +40oC (104oF). 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 by extra mechanical stops.
621 Axis 1
2 stops which allow the working range to be restricted in any increment of 20o.
622 Axis 2
6 stops which allow the working range to be restricted in increments of 20o. Each stop
decreases the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
623 Axis 3
6 stops which allow the working range to be restricted in increments of 20o. Each stop
decreases the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
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
Product Specification IRB 640 M98/BaseWare OS 3.1
53
Specification of Variants and Options
640 CABLE MANIPULATOR – CONTROLLER
The cables between the manipulator and the controller can be connected as follows:
65x External connectors
The cables are connected to 64-pin 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:
7m
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. These are connected in a chain to a connector
(CAN 3 or CAN 2, see Figure 31) 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. Measures according to the figure below. For more details, see
Technical Specification 3.10. External enclosure must provide protection class IP 54
and EMC shielding.
54
68A-F
Digital 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.
68U
Allen Bradley Remote I/O
68V-X
Interbus-S Slave
68Y-Z
Profibus DP Slave
69A-B
Encoder unit
Product Specification IRB 640 M98/BaseWare OS 3.1
Specification of Variants and Options
EN 50022 mounting rail
195
203
49
Figure 33 Dimensions for units 68A-68T.
EN 50022 mounting rail
170
115
49
Figure 34 Dimension for units 68U-Z and 69.
720 EXTRA DOCUMENTATION
Gxy
Product Manual IRB 640, including Product Specification.
919 MOUNTING OF TOOL SYSTEM ON ROBOT BEFORE DELIVERY
Mounting of extra equipment ordered from ABB Flexible Automation/U.
Product Specification IRB 640 M98/BaseWare OS 3.1
55
Specification of Variants and Options
56
Product Specification IRB 640 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 640 M98/BaseWare OS 3.1
57
Accessories
58
Product Specification IRB 640 M98/BaseWare OS 3.1
Product Specification RobotWare
CONTENTS
Page
1 Introduction ..................................................................................................................... 3
2 BaseWare OS ................................................................................................................... 5
2.1 The Rapid Language and Environment .................................................................. 5
2.2 Exception handling ................................................................................................. 6
2.3 Motion Control ....................................................................................................... 7
2.4 Safety ...................................................................................................................... 9
2.5 I/O System .............................................................................................................. 10
3 BaseWare Options ........................................................................................................... 11
3.1 Advanced Functions 3.1 ......................................................................................... 11
3.2 Advanced Motion 3.1 ............................................................................................. 16
3.3 Multitasking 3.1...................................................................................................... 19
3.4 FactoryWare Interface 3.1 ...................................................................................... 20
3.5 RAP Communication 3.1........................................................................................ 22
3.6 Ethernet Services 3.1 .............................................................................................. 23
3.7 Load Identification and Collision Detection 3.1 (LidCode)................................... 24
3.8 ScreenViewer 3.1.................................................................................................... 25
3.9 Conveyor Tracking 3.1 ........................................................................................... 27
3.10 I/O Plus 3.1 ........................................................................................................... 28
4 ProcessWare..................................................................................................................... 29
4.1 ArcWare 3.1............................................................................................................ 29
4.2 ArcWare Plus 3.1 ................................................................................................... 32
4.3 SpotWare 3.1.......................................................................................................... 33
4.4 SpotWare Plus 3.1................................................................................................... 37
4.5 GlueWare 3.1 ......................................................................................................... 38
4.6 PaintWare 3.1.......................................................................................................... 40
4.7 PalletWare............................................................................................................... 42
5 Memory and Documentation ......................................................................................... 45
5.1 Available memory................................................................................................... 45
5.2 Teach Pendant Language ........................................................................................ 46
5.3 Robot Documentation............................................................................................. 46
6 DeskWare ......................................................................................................................... 47
6.1
6.2
6.3
6.4
6.5
DeskWare Office 3.0 .............................................................................................. 47
Programming Station 3.0........................................................................................ 50
Training Center 3.0................................................................................................. 56
Library 3.0 .............................................................................................................. 58
Robot Lab 3.0 ......................................................................................................... 60
Product Specification RobotWare for BaseWare OS 3.1
1
Product Specification RobotWare
7 FactoryWare ....................................................................................................................
7.1 RobComm 3.0 ........................................................................................................
7.2 RobView 3.1 ...........................................................................................................
7.3 DDE Server 2.3 ......................................................................................................
7.4 ScreenMaker 3.0.....................................................................................................
8 Index.................................................................................................................................
2
63
63
67
74
78
79
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
TrueMoveTM
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).
QuickMoveTM
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
18
Resetting the work area for an axis
Running an axis independently to an absolute position
Running an axis independently for a specified distance
Running an axis independently to a position within one
revolution, without taking into consideration the number of turns
the axis had rotated earlier
Running an axis continuously in independent mode
Checking whether or not an independent axis has reached the
programmed position
Checking whether or not an independent axis has reached the
programmed speed
Activating path correction
Changing path correction
Read current path correction
Deactivating path correction
Removes all correction generators
Product Specification RobotWare 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
Standard protocols
SLIP
Ethernet
RS232/RS422
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
24
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.
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: ###
PHASES
SQUEEZE
PREHEAT
COOLING
## HEAT
COLD
LASTCOLD
POSTHEAT
HOLD
Next
View
File
|
|
|
|
|
|
|
|
|
XT
##
##
##
##
##
##
##
##
|
|
|
|
|
|
|
|
|
|
CURENT (A)
START | END
|
####
|
| ####
####
|
|
|
####
| ####
|
Prev.
Heat stepper: ###
interpolated: ##
|
| Tolerance: ###%
| Force: ###daN
| Forge: ###daN
|
| Fire chck: ###
|
| Err allow: ###%
| Numb err: ###
(Copy)
Product Specification RobotWare for BaseWare OS 3.1
Valid
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.
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.
30
Digital outputs
Power on/off
Gas on/off
Wire feed on/off
Wire feed direction
Weld error
Error information
Weld program number
Description
Turns weld on or off
Turns gas on or off
Turns wire feed on or off
Feeds wire forward/backward
Weld error
Digital outputs for error identification
Parallel port for selection of program number, or
3-bit pulse port for selection of program number, or
Serial CAN/Devicenet communication
Digital inputs
Arc OK
Voltage OK
Current OK
Water OK
Gas OK
Wire feed OK
Manual wire feed
Weld inhibit
Weave inhibit
Stop process
Wirestick error
Supervision inhibit
Torch collision
Description
Arc established; starts weld motion
Weld voltage supervision
Weld current supervision
Water supply supervision
Gas supply supervision
Wire supply supervision
Manual command for wire feed
Blocks the welding process
Blocks the weaving process
Stops/inhibits execution of arc welding instructions
Wirestick supervision
Program execution without supervision
Torch collision supervision
Analog outputs
Voltage
Wire feed
Current
Voltage adjustment
Current adjustment
Description
Weld voltage
Velocity of wire feed
Weld current
Voltage synergic line amplification
Current synergic line amplification
Product Specification RobotWare for BaseWare OS 3.1
ArcWare 3.1
Analog inputs (cont.)
Description (cont.)
Voltage
Weld voltage measurement for monitoring and
supervision
Weld current measurement for monitoring and
supervision
Current
RAPID instructions included in this option
ArcL
ArcC
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
32
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
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
34
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
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
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
Digital output groups
program no.
initiate
Description
weld program number
used for several weld timers
Digital inputs
weld ready 1
weld ready 2
tip 1 open
tip 2 open
tip 1 retract
tip 2 retract
p1 OK
p2 OK
p3 OK
p4 OK
timer OK
flow OK
temp OK
current OK
Description
weld, started with start 1, is finished
weld, started with start 2, is finished
the gun (tip 1) is open
the gun (tip 2) is open
the gun (tip 1) opened to retract stroke
the gun (tip 2) opened to retract stroke
pressure 1 is reached
pressure 2 is reached
pressure 3 is reached
pressure 4 is reached
the weld timer is ready to weld
no problem with the water supply
no over-temperature
the weld current is within permissible tolerances
User defined routines
The following routines are predefined but can be adapted to suit the current installation.
Routine
preweld supervision
postweld supervision
init supervision
motor on action
motor off action
process OK action
process error action
current enable action
current disable action
close gun
open gun
set pressure
service close gun
service open gun
service weld fault
Description
supervision to be done before welding
supervision to be done after welding
supervision to be done for a warm start
action to be taken for Motors On
action to be taken for Motors Off
action to be taken for welding sensor OK
action to be taken for a process error
action to be taken for current enable
action to be taken for current disable
definition of gun closing
definition of gun opening
definition of gun pressure setting
error handling when gun pressure is not achieved
error handling at timeout for gun opening
error handling at timeout for weld-ready signal
The option Advanced functions is included.
Product Specification RobotWare for BaseWare OS 3.1
35
SpotWare 3.1
RAPID instructions included in this option
SpotL
36
Spot welding with linear movement
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
Description
Glue flow reference gun 1
Glue flow reference gun 1
Glue flow reference gun 2
Glue flow reference gun 2
Digital outputs
gun 1 on/off
gun 2 on/off
overspeed error
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
process error
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
40
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,
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
43
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
PAL_DYN.sys
PAL_SCR.sys
Generated from PalletWizard:
PAL_CELL.sys
PAL_CYC.sys
Templates to be completed by the system integrator concerning work object data, tool
data, user routines including communication with external equipment etc.:
PAL_USRR.sys
PAL_USRT.sys
Modules and code not included in PalletWare
In addition to the modules listed above, there are some modules which are not included
in the PalletWare delivery, but which must be written by the system integrator for
specific installations. These are:
- The “main” module, including the main routine. In this routine all logic for
working with parallel and simultaneous pallet cycles must be coded by the system integrator, including code required for operator messages, error handling
and product changes.
- A system module holding different operator dialogues, which may be called
from the main routine in order to change or check pallet cycles or to handle error
situations.
System requirements for option PalletWare
- Option ScreenViewer.
44
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
+8 MB
Total memory
8+8=16 MB
(option 402)
8+16=24 MB
(option 403)
Program memory without
options
2.5 MB
(ram disk=0.5 MB)
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.
Option
Program memory
Base system
335 kB
Multitasking
80 kB/task (including task 1)
Advanced Functions
20 kB
GlueWare
125 kB
SpotWare
SpotWare Plus
370 kB
390 kB
Ram disk
Remark
145 kB (225 kB if
memory option 403
is chosen)
30 kB
Including Advanced
Functions
55 kB
Including Multitasking with two spotware tasks (one
process and one
supervision task).
75 kB
Including Multitasking with two spotware tasks (one
process and one
supervision task).
Including Multitasking with five spotware tasks (four
process and one
supervision task).
SpotWare Plus
730 kB
75 kB
Load Identification and
Collision Detection
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
User Preferences
Library
Training Center
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
49
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
Programming Station 3.0
Editing of background
tasks is supported
with a tabbed Tree
View.
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
51
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
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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).
Product Specification RobotWare for BaseWare OS 3.1
53
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.
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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
55
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.
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.
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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.
Product Specification RobotWare for BaseWare OS 3.1
57
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.
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.
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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
59
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.
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Product Specification RobotWare for BaseWare OS 3.1
Robot Lab 3.0
Cycle Time
Clock controls
Dynamic display
of robot in motion
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
61
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.
Product Specification RobotWare for BaseWare OS 3.1
63
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
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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).
Product Specification RobotWare for BaseWare OS 3.1
65
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.
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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.
Product Specification RobotWare for BaseWare OS 3.1
67
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.
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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.
Product Specification RobotWare for BaseWare OS 3.1
69
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.
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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.
Product Specification RobotWare for BaseWare OS 3.1
71
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.
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.
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Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1
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 keypassword. (Will run for five hour intervals without
password or key)
User security:
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
73
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.
Product Specification RobotWare for BaseWare OS 3.1
75
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)
Product Specification RobotWare for BaseWare OS 3.1
77
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
1 General ............................................................................................................................. 3
1.1 Introduction ........................................................................................................... 3
2 Applicable Safety Standards .......................................................................................... 3
3 Fire-Extinguishing........................................................................................................... 4
4 Definitions of Safety Functions ...................................................................................... 4
5 Safe Working Procedures ............................................................................................... 5
5.1 Normal operations ................................................................................................. 5
6 Programming, Testing and Servicing ............................................................................ 5
7 Safety Functions .............................................................................................................. 6
7.1 The safety control chain of operation .................................................................... 6
7.2 Emergency stops.................................................................................................... 7
7.3 Mode selection using the operating mode selector................................................ 7
7.4 Enabling device ..................................................................................................... 8
7.5 Hold-to-run control................................................................................................ 8
7.6 General Mode Safeguarded Stop (GS) connection................................................ 9
7.7 Automatic Mode Safeguarded Stop (AS) connection ........................................... 10
7.8 Limiting the working space ................................................................................... 10
7.9 Supplementary functions ....................................................................................... 10
8 Safety Risks Related to End Effectors........................................................................... 10
8.1 Gripper................................................................................................................... 10
8.2 Tools/workpieces ................................................................................................... 11
8.3 Pneumatic/hydraulic systems ................................................................................ 11
9 Risks during Operation Disturbances........................................................................... 11
10 Risks during Installation and Service ......................................................................... 11
11 Risks Associated with Live Electric Parts ................................................................... 12
12 Emergency Release of Mechanical Arm ..................................................................... 13
13 Limitation of Liability................................................................................................... 13
14 Related Information...................................................................................................... 13
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.
K2
K1
K1
Drive
Unit
M
K2
Interlocking
EN RUN
&
&
Man2
Man1
+
+
LIM1
Auto1
TPU
En1
ES1
GS1
AS1
LIM2
External
contactors
TPU
En2
ES2
GS2
Auto2
AS2
The status of the switches is indicated by LEDs on top of the panel 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
Described in:
Installation of safety devices
Product Manual - Installation and
Commissioning
Changing robot modes
User’s Guide - Starting up
Limiting the working space
Product Manual - Installation and
Commissioning
Product Manual
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 2000
IRB 2400
IRB 3000
IRB 3400
IRB 4400
IRB 6000
IRB 6400
IRB 6400C
IRB 640
manufactured by ABB Robotics Products AB 721 68 Västerås, Sweden
with serial No.
We reserve all rights in this document and in the
information contained therein. Reproduction, use or
disclosure to third parties without express authority is
strictly forbidden.  ABB Robotics Products AB
Label with
serial number
is intended to be incorporated into machinery or assembled with other machinery to constitute
machinery covered by this directive and must not be put into service until the machinery into
which it is to be incorporated has been declared in conformity with the provisions of the
directive, 91/368 EEC.
Applied harmonised standards in particular:
FO
R
IN
FO
R
M
AT
IO
N
Safety of machinery, basic terminology
Safety of machinery, technical principles/specifications, emergency stop
Safety of machinery, emergency stop equipment
Safety of machinery, temperatures of surfaces
Safety of machiney, ergonomic design principles
Robot safety
Electrical equipment for industrial machines
Safety of machinery, two-hand control device
Safety of machinery, fixed / moveable guards
Safety of machinery, safety related parts of the control system
EMC, Generic emission standard. Part 2: Industrial environment
Radiated emission enclosure
Conducted emission AC Mains
EMC, Generic immunity standard. Part 2: Industrial environment
Electrostatic discharge immunity test
Radiated, radio-frequency, electromagnetic field immunity yest
Radeated electromagnetic field from digital radio telephones, immunity test
Electrical fast transient/burst immunity test
Conducted disturbences induced by radio-frequency fields, immunity test
O
N
LY
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
Prepared
Responsible department
M Jonsson, 970904
SEROP/K
Approved by,date
Take over department
K-G Ramström, 970905
Technical Provisions
Title
Declaration by the manuf.
Page
1
Product Design Responsible
No.of pages
Status
Tillverkardeklaration
APPROVED
Document No
ABB Robotics Products
1
Rev. ind.
3HAB 3585-1
08
ABB ROBOTICS PRODUCTS AB
Robot type:
Revision:
For RAC:
RAC Ref no:
Tested and approved:
Date
CONFIGURATION LIST
Manufact order no:
Serial no:
Sales order no:
Name
MANIPULATOR:
CONTROL SYSTEM:
To the User
ROBOT SYSTEM:
The Configuration List is an individual specification of the robot
system delivered regarding configuration and extent.
Date
Delivery from factory:
On delivery, the complete document is placed in the robot controller.
Delivery to customer:
Acceptance by customer:
Customer information:
Customer:
Address:
OPTIONS/DOCUMENTATION
QTY
OPTION/PARTNO
REVISION
DESCRIPTION
System Description
CONTENTS
Page
1 Structure .......................................................................................................................... 3
1.1 Manipulator ............................................................................................................ 3
1.2 Controller................................................................................................................ 7
1.3 Electronics unit ....................................................................................................... 8
2 Computer System ............................................................................................................ 11
3 Servo System.................................................................................................................... 13
3.1 Principle function ................................................................................................... 13
3.2 Regulation............................................................................................................... 13
3.3 Controlling the robot .............................................................................................. 13
3.4 Overload protection ................................................................................................ 14
4 I/O System........................................................................................................................ 15
5 Safety System................................................................................................................... 17
5.1 The chain of operation............................................................................................ 17
5.2 MOTORS ON and MOTORS OFF modes............................................................. 18
5.3 Safety stop signals .................................................................................................. 18
5.4 Limitation of velocity ............................................................................................. 19
5.5 ENABLE ................................................................................................................ 19
5.6 24 V supervision..................................................................................................... 19
5.7 Monitoring .............................................................................................................. 19
6 External Axes................................................................................................................... 21
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 sections 1.1 and 1.2.
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
Lower arm
Axis 2
Motor axis 1
Motor axis 2
Motor axis 3
Axis 1
Base
Figure 1 The motion patterns of the IRB 1400 and IRB 140.
Product Manual
3
Structure
System Description
Motor unit axis 4
Motor unit axis 5
Motor unit axis 6
Upper arm
Axis 4 Axis 3
Axis 6
Axis 5
Motor unit and
gearbox axis 1
Lower arm
Axis 2
Motor unit and
gearbox axis 2
Motor unit and
gearbox axis 3
Axis 1
Base
Figure 2 The motion patterns of the IRB 2400.
Axis 5
Upper arm
Axis 4
Motor axis 4
Motor axis 5
Motor axis 6
Axis 6
Axis 3
Lower arm
Axis 2
Motor axis 1
Motor axis 3
Axis 1
Motor axis 2
Base
Figure 3 The motion patterns of the IRB 4400.
4
Product Manual
System Description
Structure
Axis 3
Upper arm
Motor axis 5
Motor axis 4
Axis 4
Axis 5
Motor axis 6
Axis 6
Axis 2
Motor axis 1
Motor axis 2
Lower arm
Motor axis 3
Axis 1
Base
Figure 4 The motion patterns of the IRB 6400.
Axis 3
Upper arm
Motor axis 6
Axis 6
Axis 2
Motor axis 2
Motor axis 3
Lower arm
Motor axis 1
Axis 1
Figure 5 The motion patterns of the IRB 640.
Product Manual
5
Structure
System Description
Motor 1(X)-axis
Motor 3(Z)-axis
Motor 2(Y)-axis
Motor 4(C)-axis
2(Y)-axis
3(Z)-axis
4(C)-axis
1(X)-axis
Figure 6 The motion patterns of the IRB 840/A.
Axis 2
Axis 3
Axis 2
Upper arm (x3)
Y
Axis 3
Base box
Motors
encapsulated
Bars (x3)
Axis 1
Axis 4,
telescopic shaft
(option)
Swivel
X
Z
Figure 7 The motion patterns of the IRB 340.
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 8 shows the location of the various components on the cabinet.
Teach pendant
Operator’s panel
Mains switch
Disk drive
Manipulator
connection
Figure 8 The exterior of the cabinet showing the location of the various units.
Product Manual
7
Structure
System Description
1.3 Electronics unit
Optional board
Optional board
Main computer
Memory board
Supply
unit
Robot computer
Drive module 1
Drive module 2
Drive module 3
DC link
All control and supervisory electronics, apart from the serial measurement board,
which is located inside the manipulator, are gathered together inside the controller.
Transformer
Figure 9 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 boardsCommunication 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.
8
Product Manual
System Description
Structure
Lithium batteries
I/O units (x4)
AC connection
Panel unit
Motors On and brake contactors
Floppy disk
Figure 10 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
10
System Description
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 functions for coordinating and regulating the axis movements. Figure 11 shows how the
computer system communicates with the other units.
Main
computer
board
Memory
board
Main computer
Robot
computer
board
Network I/O
computer
Axis computer
I/O computer
Teach pendant
I/O units
Drive
units
Serial measurement
board
Disk drive
Figure 11 The interfaces of the computer system.
Product Manual
11
Computer System
12
System Description
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
between axes. See Figure 12.
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.
Computer
Rotor position
Serial measurement
board
Torque reference
DC link
Drive Unit
M
R
AC OPERATION
DC link
TORQUE
reference
M
+
CURRENT
ESTIMATOR
PWM
+
+
M
ROTOR
POSITION
-
W
PWM
-
+
CURRENT
REGULATOR
M
+
U
M
V
PWM
MAIN
CIRCUITS
Figure 12 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
RS 422
RS 232
General
Serial ports
Distributed
I/O bus
CAN/
DeviceNet
SIO2
SIO1
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
Figure 13 Overview of the I/O system.
Product Manual
15
I/O System
16
System Description
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 14 below illustrates an outline principal circuit with available customer contacts.
LS
Solid state switches
Contactor
ES
2nd
chain
interlock
GS
Drive
unit
&
TPU En
EN
AS
RUN
M
Computer commands
Auto
Manual
Operating
mode selector
LS
= Limit switch
AS
= Automatic mode safeguarded space Stop
TPU En= Enabling device, teach pendant unit
GS
= General mode safeguarded space Stop
ES
= Emergency Stop
Figure 14 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:
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.
18
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
20
System Description
Product Manual
System Description
External Axes
6 External Axes
Not valid for IRB 340(r)!
External axes are controlled by drive units, mounted either inside the controller or outside in a separate enclosure, see Figure 15.
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.
Measurement System 2
Drive System
1, inside
robot cabinet
Not supplied on delivery
Alt.
Contains
no CPU
IRB
Drive System 2 inside
external axes cabinet
Measurement
System 1
Not supplied on delivery
Figure 15 Outline diagram, external axes.
Product Manual
21
External Axes
22
System Description
Product Manual
Installation and Commissioning
CONTENTS
Page
1 Transporting and Unpacking ......................................................................................... 5
1.1 Stability / risk of tipping......................................................................................... 6
1.2 System diskettes ..................................................................................................... 6
2 On-Site Installation ......................................................................................................... 7
2.1 Lifting the manipulator and controller.................................................................... 7
2.2 Assembling the robot.............................................................................................. 12
2.2.1 Manipulator.................................................................................................. 12
2.2.2 Controller ..................................................................................................... 13
2.3 Stress forces............................................................................................................ 14
2.3.1 Stiffness........................................................................................................ 14
2.3.2 All versions .................................................................................................. 14
2.4 Amount of space required....................................................................................... 15
2.4.1 Manipulator.................................................................................................. 15
2.4.2 Controller ..................................................................................................... 16
2.5 Manually engaging the brakes................................................................................ 17
2.6 Restricting the working space................................................................................. 18
2.6.1 Axis 1 ........................................................................................................... 18
2.6.2 Axes 2 and 3................................................................................................. 19
2.7 Mounting holes for equipment on the manipulator ................................................ 20
2.7.1 Quality of screws for fitting extra equipment .............................................. 20
2.8 Loads ...................................................................................................................... 21
2.9 Connecting the controller to the manipulator ......................................................... 22
2.9.1 Connection on left-hand side of cabinet ...................................................... 22
2.10 Dimensioning the safety fence ............................................................................. 22
2.11 Mains power connection....................................................................................... 23
2.11.1 Connection to the mains switch ................................................................. 23
2.11.2 Connection via a power socket .................................................................. 24
2.12 Inspection before start-up ..................................................................................... 24
2.13 Start-up ................................................................................................................. 25
2.13.1 General ....................................................................................................... 25
2.13.2 Updating the revolution counter ................................................................ 26
2.13.3 Checking the calibration position .............................................................. 30
2.13.4 Alternative calibration positions ................................................................ 30
2.13.5 Operating the robot .................................................................................... 30
3 Connecting Signals .......................................................................................................... 31
3.1 Signal classes.......................................................................................................... 31
Product Manual IRB 640
1
Installation and Commissioning
CONTENTS
Page
3.2
3.3
3.4
3.5
Selecting cables ......................................................................................................
Interference elimination .........................................................................................
Connection types ....................................................................................................
Connections ............................................................................................................
3.5.1 To screw terminal.........................................................................................
3.5.2 To connectors (option) .................................................................................
3.6 Customer connections on manipulator...............................................................
3.7 Connection to screw terminal.................................................................................
3.8 The MOTORS ON / MOTORS OFF circuit ..........................................................
3.9 Connection of safety chains ...................................................................................
3.9.1 Connection of ES1/ES2 on panel unit .........................................................
3.9.2 Connection to Motor On/Off contactors ......................................................
3.9.3 Connection to operating mode selector .......................................................
3.9.4 Connection to brake contactor .....................................................................
3.10 External customer connections.............................................................................
3.11 External safety relay .............................................................................................
3.12 Safeguarded space stop signals ............................................................................
3.12.1 Delayed safeguarded space stop ................................................................
3.13 Available voltage ..................................................................................................
3.13.1 24 V I/O supply..........................................................................................
3.13.2 115/230 V AC supply ................................................................................
3.14 External 24 V supply ............................................................................................
3.15 Connection of extra equipment to the manipulator ..............................................
3.15.1 Connections on upper arm. ........................................................................
3.15.2 Connections on upper arm with CanBus. ..................................................
3.15.3 Connection of signal lamp on upper arm (option) .....................................
3.16 Distributed I/O units .............................................................................................
3.16.1 General.......................................................................................................
3.16.2 Sensors .......................................................................................................
3.16.3 Connection and address keying of the CAN-bus.......................................
3.16.4 Digital I/O DSQC 328 (optional)...............................................................
3.16.5
3.16.6
3.16.7
3.16.8
3.16.9
2
AD Combi I/O DSQC 327 (optional) ........................................................
Analog I/O DSQC 355 (optional)..............................................................
Encoder interface unit, DSQC 354 ............................................................
Relay I/O DSQC 332 .................................................................................
Digital 120 VAC I/O DSQC 320 ...............................................................
31
32
32
33
33
33
35
40
41
42
43
44
44
44
45
48
49
49
49
49
50
50
51
51
52
53
54
54
54
55
57
60
63
67
70
73
Product Manual IRB 640
Installation and Commissioning
CONTENTS
Page
3.17 Field bus units....................................................................................................... 76
3.17.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 35076
3.17.2 Interbus-S, slave DSQC 351 ...................................................................... 78
3.17.3 Profibus-DP, slave, DSQC352 ................................................................... 81
3.18 Communication .................................................................................................... 83
3.18.1 Serial links, SIO ......................................................................................... 83
3.18.2 Ethernet communication, DSQC 336......................................................... 85
3.19 External operator’s panel...................................................................................... 87
4 Installing the Control Program...................................................................................... 89
4.1 System diskettes ..................................................................................................... 89
4.1.1 Installation procedure................................................................................... 89
4.2 Calibration of the manipulator................................................................................ 90
4.3 Cold start................................................................................................................. 90
4.4 How to change language, options and IRB types................................................... 91
4.5 How to use the disk, Manipulator Parameters ................................................ 92
4.6 Robot delivered with software installed.......................................................... 92
4.7 Robot delivered without software installed .................................................... 92
4.8 Saving the parameters on the Controller Parameter disk................................ 93
5 External Axes................................................................................................................... 95
5.1 General.................................................................................................................... 95
5.2 Easy to use kits ....................................................................................................... 97
5.3 User designed external axes. .................................................................................. 98
5.3.1 DMC-C......................................................................................................... 98
5.3.2 FBU.............................................................................................................. 99
5.3.3 Measurement System ................................................................................... 100
5.3.4 Drive System................................................................................................ 104
5.3.5 Configuration Files ...................................................................................... 111
Product Manual IRB 640
3
Installation and Commissioning
CONTENTS
Page
4
Product Manual IRB 640
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 + 45°C (manipulator)
+ 5° to + 45°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 1950 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.
Product Manual IRB 640
5
Transporting and Unpacking
Installation and Commissioning
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.
The following table shows the positions where there is a risk of tipping and refers to figures in chapter 3.8 in Product Specification IRB 640, for definition of position 0 and 5.
Working area, position 0
load = 0 kg
load = max
no
no
yes
no
Working area, position 5
load = 0 kg load = max
no
yes
= stable
= risk of tipping
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.
6
Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2 On-Site Installation
2.1 Lifting the manipulator and controller
The following lifting instructions are valid for a “naked” robot. Whenever
additional equipment is put on the robot, the centre of gravity can change and
make lifting dangerous.
Never walk under a suspended load.
If the integrated lifting ears on the front cannot be reached, the manipulator must be
reoriented to the sync position.
The best way to lift the manipulator is to use lifting straps and a traverse crane.
Attach the straps to the integrated lifting eyes on both sides of the frame (see
Figure 2). The lifting strap dimensions must comply with the applicable standards
for lifting. It is also possible to use two lifting devices (option) for use with a fork
lift truck (see Figure 4).
NB!
The right lifting device, the robot seen from behind, must be removed before
start-up, see Figure 1.
Lifting device
View from behind
Figure 1 Lifting device that must be removed.
Product Manual IRB 640
7
On-Site Installation
Installation and Commissioning
Crane lift
Length=1150
Length=950
240
700
Figure 2 Lifting the manipulator using a traverse crane.
8
Product Manual IRB 640
Installation and Commissioning
On-Site Installation
Crane lift, in calibration position
Length=1150
Length=950
Figure 3 Lifting the manipulator with the arm system in the calibration position.
Product Manual IRB 640
9
On-Site Installation
Installation and Commissioning
Fork lift
400
1120
Figure 4 Lifting the manipulator using a fork lift truck.
Crane lifting is not permitted using the fork lift arrangement.
10
Product Manual IRB 640
Installation and Commissioning
On-Site Installation
Use the four lifting devices on the cabinet or a fork lift when lifting the controller
(see Figure 5).
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 5 The maximum angle between the lifting straps when lifting the controller.
Product Manual IRB 640
11
On-Site Installation
Installation and Commissioning
2.2 Assembling the robot
2.2.1
Manipulator
The three support points of the manipulator foot shall be mounted on three flat surfaces
with a flatness within the specification. Use shims if necessary. The rest of the surface
must be flat within ± 2 mm. Footprint diagram, see Figure 6. Floor mounted models can
be tilted max. 5o.
The levelness requirement for the surface is as follows:
0.5
Y
∅ 0.2
720
415.7
D=48(3x)
D=32(3x)
100 ±0,5
Z
X
A
480±0.1
A
15
D=64 H9 (3x)
+2
0
Support surface D=85 (3x)
A-A
Guide sleeve
Figure 6 Bolting down the manipulator (dimensions in mm).
The manipulator is fixed with three M30 bolts, tightened alternately.
Suitable bolts:
M30x160 8.8 Socket screw with washer
Tightening torque:
1000 Nm
Two guide sleeves can be added to two of the bolt holes, to allow the same manipulator
to be re-mounted without program adjustment (see Figure 6).
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
When bolting a mounting plate or frame to a concrete floor, follow the general
instructions for expansion-shell bolts. The screw joint must be able to withstand the
stress loads defined in Chapter 2.3 Stress forces .
2.2.2
Controller
The controller may be secured to the floor using M10 screws, see the footprint drawing
below (dimensions in mm). See also Chapter 2.4 Amount of space required, before
assembling the controller.
400
720
Product Manual IRB 640
13
On-Site Installation
Installation and Commissioning
2.3 Stress forces
2.3.1
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 22 Hz.
TuneServo can be used for adapting the robot tuning to a non-optimal foundation.
2.3.2
All versions
Endurance load
(In operation)
Max. load
(Emergency stop)
Force xy
±12 000 N
±18 000 N
Force z
21 000 ±5 500 N
21 000 ±10000 N
Torque xy
± 32 000 Nm
±39 000 Nm
Torque z
±6 000 Nm
±13 000 Nm
Force xy and torque xy are vectors that can have any direction in the xy plane.
X
Y
Z
Figure 7 The directions of the stress forces.
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2.4 Amount of space required
The amount of working space required to operate the manipulator and controller is
illustrated in Figure 8.
The working range for axis 1 is +/- 180°.
NB: There are no software or mechanical limits for the working space under the
base of the manipulator.
2.4.1
Manipulator
IRB 640
-3
2/3 +3
-2
+2
-6
+6
TCP 0
-1
2310
+1
599
1220
2905
All dimensions refer to TCP 0 (mm)
Figure 8 The working space required for the manipulator.
Product Manual IRB 640
15
On-Site Installation
2.4.2
Installation and Commissioning
Controller
50
800
540
Cabinet extension
Option 115
800
Extended cover
Option 114
500
250
200
950
980 *
Lifting points
for forklift
* Castor wheels
500
Figure 9 The space required for the controller.
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2.5 Manually engaging the brakes
All axes come equipped with holding brakes. When the position of a manipulator axis
needs to be changed without connecting the controller, an external voltage supply
(24 V DC) must be connected to enable engagement of the brakes. The voltage supply
should be connected to the connector at the base of the manipulator (see Figure 10).
0 V B14
+24 V B16
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, illustrated above, the brakes
can be engaged separately by means of the push-buttons on the brake release unit on
the exterior of the axis 3 gear box. The push-buttons are marked with the appropriate
axis name. The names of the axes and their motion patterns are illustrated in Figure 11.
WARNING: Be very careful when engaging the brakes. The axes become activated very quickly and may cause damage or injury.
Axis 3
6
5
4
3
2
1
NB!
Buttons 4 and 5
are not connected.
Axis 2
Axis 6
Brake release unit
Axis 1
Figure 11 The robot axes and motion patterns.
Product Manual IRB 640
17
On-Site Installation
Installation and Commissioning
2.6 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, both mechanically and using software. Installation of an optional
extra stop for the main axes 1, 2 and 3 is described below.
Limiting the working space using software is described in the chapter System Parameters in the User’s Guide.
2.6.1
Axis 1
The range of rotation for axis 1 can be limited mechanically by fitting extra mechanical
stop arms.
Instructions for doing this are supplied with the kit.
IMPORTANT! The mechanical stop pin and the extra moveable mechanical stop
arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm
has been deformed.
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Product Manual IRB 640
Installation and Commissioning
2.6.2
On-Site Installation
Axes 2 and 3
The working range of axes 2 and 3 is limited by mechanical stops and can be reduced by adding
fixed mechanical stops.
The stops are mounted on the inside of the frame to each axis.
Extra stops must be mounted in a row, starting at the fixed stop.
Holes for extra stops
Figure 12 Mechanically limiting axes 2 and 3.
NB!
The robot is always delivered with one extra mechanical stop mounted for axis 3. It is not
allowed to remove it.
Product Manual IRB 640
19
On-Site Installation
Installation and Commissioning
2.7 Mounting holes for equipment on the manipulator
NB: Never drill a hole in the manipulator without first consulting maintenance staff or
the design department at ABB Flexible Automation.
260
M10 (2x) through
80
130
M10 (4x) through
200
230
126
99
45
35 100
Limit for M10 surfaces
M10 (2x)
depth 25
Limit for M10 surfaces
411
60 69
220
486
Figure 13 Holes for mounting extra equipment (dimensions in mm).
30o
D=10 H7 depth 10
8
M10 (6x) depth 18
D=80 H7
D=160 h7
60o
D=125
F-F
8
Figure 14 The mechanical interface (mounting flange) ISO 9409 (dimensions in mm).
2.7.1
Quality of screws for fitting extra equipment
When fitting tools on the manipulator’s mounting flange (see above), use only screws with
quality of 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2.8 Loads
It is important to define the loads properly (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and unnecessary stops due
to overloaded motors.
For more information see chapter 3.4 in Product Specification IRB 640 (Technical
specification) for load diagrams, permitted extra loads (equipment) and their positions.
The loads must also be defined in the software, see User´s Guide.
Product Manual IRB 640
21
On-Site Installation
Installation and Commissioning
2.9 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.
2.9.1
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 15). 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 15 Connections on the cabinet wall.
2.10 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 640 is 10 m/s.
Applicable standards are ISO/DIS 11161 (see also chapter 3.13) and prEN 999:1995.
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2.11 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.
2.11.1 Connection to the mains switch
Remove the left cover plate under the top lid. Pull the mains cable (outer diam. 10.20
mm) through the gland (see Figure 16), located on the left cabinet wall.
XT 26
PE
Cable gland
Connector
Figure 16 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 breaker (see Figure 16).
2. Connect phase
1 to L1 (N.B. Not dependent on phase sequence)
2 to L2
3 to L3
0 to XT26.N(line neutral is needed only for option 432)
and protective earth to
NOTE!
Max. cunductor size is 6 mm2 (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 640
23
On-Site Installation
2.11.2
Installation and Commissioning
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 17.
Cable connectors are supplied (option 133 - 134).
CEE connector
DIN connector
Figure 17 Mains connection via an optional wall socket.
2.12 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
External emergency stop, internal 24 V
General stop +
General stop Auto stop +
Auto stop Motor off clamping
XS3
A5-A6, B5-B6
A3-A4, B3-B4
A1-A2, B1-B2
A11-A12, B11-B12
A13-A14, B13-B14
A7-A8, B7-B8
A9-A10, B9-10
A15-A16, B15-16
Panel unit
X1.3-4, X2.3-4
X1.9-10, X2.9-10
X1.7-8, X2.7-8
X3.10-12, X4.10-12
X3.7-8, X4.7-8
X3.11-12, X4.11-12
X3.7-9, X4.7-9
X1.5-6, X2.5-6
For more information, see Chapter 3.8, The MOTORS ON / MOTORS OFF circuit and
Chapter 3.9, Connection of safety chains.
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
2.13 Start-up
2.13.1
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 18).
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.
Figure 18 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 2.13.2.
6. Check the calibration position according to section 2.13.3.
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.
9. each axis moves and is restricted as intended.
Product Manual IRB 640
25
On-Site Installation
Installation and Commissioning
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.
8. The robot is now ready for operation.
2.13.2
Updating the revolution counter
When pressing the enabling device on a new robot, a message will be displayed on the
teach pendant telling you that the revolution counters are not updated. When such a message appears, the revolution counter of the manipulator must be updated using the calibration marks on the manipulator (see Figure 23).
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 23).
When all axes have been positioned as above, the revolution counter settings are stored
using the teach pendant, as follows:
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
1. Press the Misc. window key (see Figure 19).
1
2
P1
7
8
9
4
1
5
2
0
6
3
P2
P3
Figure 19 The Misc. window key from which the Service window can be chosen.
Product Manual IRB 640
27
On-Site Installation
Installation and Commissioning
2. Select Service in the dialog box shown on the display.
3. Press Enter
.
4. Then, choose View: Calibration. The window in Figure 20 appears.
File
Edit
View
Calib
Service Calibration
Unit
Status
1(1)
IRB
Not rev. counter update
Figure 20 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.
5. Select the desired unit in the window, as in Figure 20. Choose Calib: Rev. Counter
Update. The window in Figure 21 appears.
Rev. Counter Update!
IRB
To calibrate, include axes and press OK.
Axis
Status
1(6)
X
X
X
X
1
2
3
4
5
6
Incl
Not updated
Not updated
Calibrated
Calibrated
Not updated
Not updated
All
Rev. Counter
Rev. Counter
Rev. Counter
Rev. Counter
Cancel
OK
Figure 21 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).
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Product Manual IRB 640
Installation and Commissioning
On-Site Installation
7. Confirm by pressing OK. A window like the one in Figure 22 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 22 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 2.13.3, Checking the calibration position.
10.Save the system parametrs on floppy disk.
-
*)
*) axis number
+
Figure 23 Calibration marks on the manipulator.
Product Manual IRB 640
29
On-Site Installation
2.13.3
Installation and Commissioning
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 640 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 23. If
they are not, the setting of the revolution counters must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window
and choose running axis-by-axis. Using the joystick,
move the robot so that the read-out of the positions is equal to zero. Check that the calibration marks for each axis are at the same level, see Figure 23. If they are not, the setting of the revolution counters must be repeated.
2.13.4
Alternative calibration positions
See chapter 12, Repairs.
2.13.5
Operating the robot
Starting and operating the robot is described in the User’s Guide. Before start-up, make
sure that the robot cannot collide with any other objects in the working space.
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Product Manual IRB 640
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 70o C. In addition, the
following rules apply to the cables of certain signal classes:
Power signals -Shielded cable with an area of at least 0.75 mm2 or AWG 18. Note that
any local standards and regulations concerning insulation and area must always be
complied with.
Control signals – Shielded cable.
Measuring signals – Shielded cable with twisted pair conductors.
Data communication signals – Shielded cable with twisted pair conductors. A specific cable should be used for 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 640
31
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 24 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.
+0 V
+24 V DC
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
+0 V
R
C
R 100 ohm, 1W
C 0.1 - 1 µF
> 500 V max voltage
125 V nominal voltage
Figure 24 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
32
X(T)
Screwed terminal
XP
Male (pin)
XS
Sockets (female)
Product Manual IRB 640
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 wiyh keyed screw terminals for cables with an
area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one
connection. 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 25 and Figure 16.
In each industrial connector there is space for four rows of 16 conductors with a maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when connecting
the shield to the case.
The manipulator arm is equipped with round Burndy/Framatome connectors (customer
connector not included).
Bend unused conductors backwards and attach them to the cable using a clasp, 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 640
33
Connecting Signals
Installation and Commissioning
Space for cable glands
XS 3 (safety)
Prepared for further
connectors
XS 5 (customer signals)
XS17,
CAN bus connector
XS 6 (customer power)
XS 7 (external axes)
XS 8, Position switch
XS 1, Motor cable
XS 2, Measurement system
cable
Figure 25 Positions for connections on the left-hand side of the controller.
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Product Manual IRB 640
Installation and Commissioning
Connecting Signals
3.6 Customer connections on manipulator
The hose for compressed air is integrated into the manipulator. There is an inlet at the
base and an outlet on the tilt house.
Connections: R 1/2”.
For connection of extra equipment on the manipulator there are cables integrated into
the manipulator’s cabling, and two connectors, one Burndy 23-pin UTG 018-23S and
one Burndy 12-pin UTG 014-12S.
Number of signals without CanBus : 23 signals (50 V, 250 mA), 10 power signals
(250 V, 2 A).
Number of signals with CanBus : 12 signals (50 V, 250 mA), 5 power signals
(250 V, 2 A).
R3.CP/CS
Air R1/2”
R3.CB
R1.CPV
Air R1/2”
R1.CP/CS
R1.CB
R1.SW
Figure 26 Location of customer connections.
Product Manual IRB 640
35
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:
Connector R1.CS, R1.CP. Signals on manipulator base. (Regarding Item No. see
Figure 27). Included in delivery.
Item
Name
ABB art. no.
Type
Comments
1
Female insert 40p
3HAB 7284-1
DIN 43 652
Harting
2
Hood
3HAB 7285-1
DIN 43 652
Harting (PG 29)
3
Compression gland
3HAB 7283-1
DS/55 ZU, DN
155D, E155
Novum
(PG 29 AB)
4
Socket
5217 1021-4
DIN 43 652
Harting
5
Socket
5217 1021-5
DIN 43 652
Harting
Connector R3.CS. Signals on the upper arm. (Regarding Item No. see Figure 28)
36
Item
Name
ABB art. no.
Type
Comments
1
Socket con. 23p
3HAA 2613-3
UTO 018 23 SHT
Burndy
2
Gasket
2152 0363-5
UTFD 16 B
Burndy
3
Socket
See Pin and
Socket table
below
4
Pin con. 23p
3HAA 2602-3
5217 649-34
5
Pin
See Pin and
Socket table
below
6
Adaptor
3HAA 2601-3
5217 1038-5
UTG 18 ADT
UTG 18 AD
Burndy EMC
Burndy
7
Cable clamp
5217 649-36
UTG 18 PG
Burndy
8
Shrinking hose
Shrinking hose
3HAA 2614-3
5217 1032-5
UTG 61823 PN04 Burndy EMC
UTG 61823 PN
Burndy
Bottled shaped
Angled
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
Connector R3.CP. Power signals on the upper arm. (Regarding Item No. see Figure 28)
Item
Name
ABB art. no.
Type
Comments
1
Socket con. 12p
3HAA 2613-2
UTO 014 12 SHT
Burndy
2
Gasket
5217 649-64
UTFD 13 B
Burndy
3
Socket
See Pin and
Socket table
below
4
Pin con. 12p
3HAA 2602-2
5217 649-7
UTO 61412 PN04
UTO 61412 PN
Burndy EMC
Burndy
5
Pin
See Pin and
Socket table
below
6
Adaptor
3HAA 2601-2
5217 1038-3
UTG 14 ADT
UTG 14 AD
Burndy EMC
Burndy
7
Cable clamp
5217 649-8
UTG 14 PG
Burndy
8
Shrinking hose
Shrinking hose
3HAA 2614-2
5217 1032-4
Bottled shaped
Angled
Connector R1.CPV. Power signals on the manipulator base.
(Regarding Pos see Figure 28)
Pos
Name
ABB art. no.
Type
Comments
1
Pin connector 12p
3HAA 2599-2
UTO 614 12 PN04
Burndy
2
Gasket
5217 649-64
UTFD 13 B
Burndy
3
Pin
See below
4
Socket con. 12p
3HAA 2600-2
5217 649-53
UTO 614 12S 04T
UTG 614 12 SN
Burndy EMC
Burndy
5
Sockets
See below
6
Adaptor
3HAA 2601-2
UTG 14 ADT
Burndy EMC
7
Cable clamp
5217 649-8
UTG 14 PG
Burndy
8
Shrinking hose
Shrinking hose
3HAA 2614-2
5217 1032-4
Product Manual IRB 640
Bottled shaped
Angled
37
Connecting Signals
Installation and Commissioning
Name
ABB part no.
Type
Comments
Pin
5217 649-72
5217 649-25
5217 649-70
5217 649-3
5217 649-68
5217 649-10
5217 649-31
24/26
24/26
20/22
20/22
16/20
24/26
16/20
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Ground
Burndy Ground
Socket
5217 649-73
5217 649-26
5217 649-71
5217 649-69
5217 1021-4
24/26
24/26
20/22
16/18
DIN 43 652
5217 1021-5
DIN 43 652
Burndy Machine tooling
Burndy Hand tooling
Burndy Machine tooling
Burndy Machine tooling
Tin bronze (CuSu)
0.14 - 0.5mm2 AWG 20-26
Tin bronze (CuSu)
0.5 - 1.5mm2 AWG 16-20
3
2
6
1
4
5
Figure 27 Customer connector
38
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
Customer side
4, 5
Manipulator side
1, 3
8
6
2
7
Figure 28 Burndy connector
Product Manual IRB 640
39
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)
CAN 2 (manipulator, I/O units)
CAN 3 (external I/O units)
24 V supply (2 A fuse)
115/230 V AC supply
Panel unit
I/O unit
I/O unit
I/O unit
I/O unit
Backplane
Panel unit
Backplane
Backplane
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.
X1 (SIO1)
Backplane
X2 (SIO2)
X10 (CAN3)
I/O units (x4)
X16 (CAN2)
alt. D-sub
Panel unit
WARNING
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
MS NS
EN
ES1 ES2 GS1 GS2 AS1 AS2
X1 - 4
X5
XT5, customer signals
XT6, customer power
XT8, position switch
X8
X6 CONTROL PANEL
X9 (CAN1))
XT21 (115/230 V ACsupply)
XT31 (24V supply)
Figure 29 Screw terminal locations.
40
Product Manual IRB 640
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 30 shows an outline principal diagram of the available customer connections, AS, GS and
ES.
LS
Solid state switches
Contactor
ES
2nd
chain
interlock
GS
TPU En
&
EN RUN
Computer commands
AS
Auto
Operating
mode selector
Drive
unit
Manual
M
LS
= Limit switch
AS
= Automatic mode safeguarded space Stop
TPU En= Enabling device, teach pendant unit
GS
= General mode safeguarded space Stop
ES
= Emergency Stop
Figure 30 MOTORS ON /MOTORS OFF circuit.
Product Manual IRB 640
41
Connecting Signals
Installation and Commissioning
3.9 Connection of safety chains
24 V *
X3:12
X4:12
24 V
Ext LIM1
X1:4 3
K1
0V
see 3.9.1
ES1
X3:10
8
+ Opto
isol.
-
GS1
&
TPU En1
11
9
+ Opto
isol.
-
EN
RUN
AS1
Auto1
K1
Interlocking
K2
Man1
External contactors
X2:5 6
CONT1
0V
X1:5
24 V
6
CONT2
Ext LIM2
X2:4 3
0V
K2
24V
see 3.9.1
8
Drive unit
ES2
X4:10
+ Opto
isol.
-
GS2
M
&
TPU En2
11
+
9
-
Opto AS2
isol.
Technical data per chain
Auto2
Man2
X3:7 *
X4:7
0V
*)
Supply from internal 24V (X3/X4:12) and 0 V
(X3/X4:7) is displayed.
When external supply of GS and AS, X3/X4:10,11 is
connected to 24 V and X3/X4:8,9 is connected to
external 0 V
X1-X4 connection tables, see section 3.10.
Limit switch: load
max. V drop
300 mA
1V
External contactors: load
max. V drop
10 mA
4V
GS/AS load at 24V
25 mA
GS/AS closed “1”
> 18 V
GS/AS open “0”
<5V
External supply of GS/AS
max. +35VDC
min. -35VDC
Max. potential relative to
the cabinet earthing and
other group of signals
300 V
Signal class
control signals
Figure 31 Diagram showing the two-channel safety chain.
42
Product Manual IRB 640
Installation and Commissioning
3.9.1
Connecting Signals
Connection of ES1/ES2 on panel unit
External
24V 0V
Internal
24V 0V
TPU
External
Cabinet
X1:9
X1:10
E-stop relay
X1:7
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
Chain 1
X1:8
X1:2
ES1 out
X1:1
Internal
0V 24V External
TPU
Cabinet
X2:9
X2:10
E-stop relay
Chain 2
X2:8
X2:7
Technical data
ES1 and 2 out max. voltage
120 VAC or 48 VDC
ES1 and 2 out max. current
120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relays =
min 22 V between terminals X1:9,8 and
X2:9,8 respectively
Rated current per chain
40 mA
Max. potential relative to the
cabinet earthing and other
groups of signals
300 V
Signal class
control signals
X2:2
ES2 out
X2:1
Figure 32 Terminals for emergency circuits.
Product Manual IRB 640
43
Connecting Signals
3.9.2
Installation and Commissioning
Connection to Motor On/Off contactors
K1 (Motor On/Off 1)
Technical data
K2 (Motor On/Off 2)
Max. voltage
48V DC
Max. current
4A
Max. potential relative to the cabinet
earthing and other
groups of signals
X3:2
1
X4:2
1
Signal class
300V
control
Figure 33 Terminals for customer use.
3.9.3
Connection to operating mode selector
X3:3
Auto1
4
5
MAN1
6
100%
X4:3
Auto2
4
5
MAN2
100%
Technical data
Max. voltage
48V DC
Max. current
4A
Max. potential relative to the cabinet
earthing and other
groups of signals
300V
Signal class
control
6
Figure 34 Terminals customer use.
3.9.4
Connection to brake contactor
Technical data
K3 (Brake)
X1:12
11
Max. voltage
48V DC
Max. current
4A
Max. potential relative to the cabinet
earthing and other
groups of signals
Signal class
300V
control
Figure 35 Terminal for customer use.
44
Product Manual IRB 640
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
X1
X2
MS NS
ES1 ES2 GS1 GS2 AS1 AS2
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
Chain status
LED´s
X3
X4
= jumper
Customer connections: X1 - X4, located on the panel unit.
The signal names refer to the circuit diagram in chapter 11.
X1
Signal name
Pin
Comment
ES1 out:B
1
Emergency stop out chain 1
ES1 out:A
2
Emergency stop out chain 1
Ext. LIM1:B
3
External limit switch chain 1
Ext. LIM1:A
4
External limit switch chain 1
0V
5
0V external contactor 1
CONT1
6
External contactor 1
Int. 0V ES1
7
Internal supply 0V of emergency stop chain 1
Ext. 0V ES1
8
External supply 0V of emergency stop chain 1
Ext. ES1 IN
9
External emergency stop in chain 1
Ext. ES1 OUT
10
External emergency stop out chain 1
Ext. BRAKE B
11
Contactor for external brake
Ext. BRAKE A
12
Contactor for external brake
Product Manual IRB 640
45
Connecting Signals
Installation and Commissioning
X2
Signal name
Pin
Comment
ES2 out:B
1
Emergency stop out chain 2
ES2 out:A
2
Emergency stop out chain 2
Ext. LIM2:B
3
External limit switch chain 2
Ext. LIM2:A
4
External limit switch chain 2
24V panel
5
24V external contactor 2
CONT2
6
External contactor 2
Int. 24V ES2
7
Internal supply 24V of emergency stop chain 2
Ext. 24V ES2
8
External supply 24V of emergency stop chain 2
Ext. ES2 IN
9
External emergency stop in chain 2
Ext. ES2 OUT
10
External emergency stop out chain 2
11
Not used
12
Not used
X3
Signal name
46
Pin
Comment
Ext. MON 1:B
1
Motor contactor 1
Ext. MON 1:A
2
Motor contactor 1
Ext. com 1
3
Common 1
Ext. auto 1
4
Auto 1
Ext. man 1
5
Manual 1
Ext. man FS 1
6
Manual full speed 1
0V
7
0V to auto stop and general stop
GS1-
8
General stop minus chain 1
AS1-
9
Auto stop minus chain 1
GS1+
10
General stop plus chain 1
AS1+
11
Auto stop plus chain 1
24V panel
12
24V to auto stop and general stop
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
X4
Signal name
Pin
Comment
Ext. MON 2:B
1
Motor contactor 2
Ext. MON 2:A
2
Motor contactor 2
Ext. com 2
3
Common 2
Ext. auto 2
4
Auto 2
Ext. man 2
5
Manual 2
Ext. man FS 2
6
Manual full speed 2
0V
7
0V to auto stop and general stop
GS2-
8
General stop minus chain 2
AS2-
9
Auto stop minus chain 2
GS2+
10
General stop plus chain 2
AS2+
11
Auto stop plus chain 2
24V panel
12
24V to auto stop and general stop
Product Manual IRB 640
47
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
X2:6
CONT2
24 V X2:5
Ext MON 2
X4:2
0V
K2
X4:1
X3:2
K1
Ext MON 1
X3:1
24 V
0 V X1:5
CONT1 X1:6
Robot 1
Robot 2
(only one channel displayed)
External
supply
AS GS
AS GS
ES out
ES out
Safety relay
External
supply
Cell ES
To other
equipment
Safety gate
Figure 36 Diagram for using external safety relays.
48
Product Manual IRB 640
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
Product Manual IRB 640
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)
49
Connecting Signals
Installation and Commissioning
24 V I/O available for customer connections at:
XT.31.2
XT.31.1
XT.31.4
3.13.2
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)
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
XT.21.6-8
XT.21.9-13
230 V (3.15 A)
115 V (6.3 A)
N (connected to cabinet structure)
3.14 External 24 V supply
An external supply must be used in the following cases:
• When the internal supply is insufficient
• When the emergency stop circuits must be independent of whether or not the robot
has power on, for example.
• When there is a risk that major interference can be carried over into the internal
24 V supply
An external supply is recommended to make use of the advantages offered by the
galvanic insulation on the I/O units or on the panel unit.
The neutral wire in the external supply must be connected in such a way as to prevent the
maximum permitted potential difference in the chassis earth being exceeded. For example,
a neutral wire can be connected to the chassis earth of the controller, or some other common
earthing point.
Technical data:
Potential difference to chassis earth:
Permitted supply voltage:
50
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 640
Installation and Commissioning
Connecting Signals
3.15 Connection of extra equipment to the manipulator
Technical data for customer connections
Customer Power CP
Conductor resistance
Max. voltage
Max. current
<0,5 ohm, 0,241 mm2
250 V AC
2A
Customer Signals CS
Conductor resistance
Max. voltage
Max. current
3.15.1
<3 ohm, 0.154 mm2
50 V AC / DC
250 mA
Connections on upper arm.
R3.CP/CS
Air R1/2”
Figure 37 Customer connections on upper arm.
Signal name
Power supply
CPA
CPB
CPC
CPD
CPE
CPF
CPJ
CPK
CPL
CPM
Customer terminal Customer contact on Customer contact
controller,
manipulator base, R1 on upper arm, R3
see Figure 29
(cable not supplied)
XT6.1
XT6.2
XT6.3
XT6.4
XT6.5
XT6.6
XT6.7
XT6.8
XT6.9
XT6.10
Product Manual IRB 640
R1.CP/CS.A1
R1.CP/CS.B1
R1.CP/CS.C1
R1.CP/CS.D1
R1.CP/CS.A2
R1.CP/CS.B2
R1.CP/CS.C2
R1.CP/CS.D2
R1.CP/CS.A3
R1.CP/CS.B3
R3.CP.A
R3.CP.B
R3.CP.C
R3.CP.D
R3.CP.E
R3.CP.F
R3.CP.J
R3.CP.K
R3.CP.L
R3.CP.M
51
Connecting Signals
Signals
CSA
CSB
CSC
CSD
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
CSN
CSP
CSR
CSS
CST
CSU
CSV
CSW
CSX
CSY
CSZ
3.15.2
XT5.1.1
XT5.1.2
XT5.1.3
XT5.1.4
XT5.1.5
XT5.1.6
XT5.1.7
XT5.1.8
XT5.1.9
XT5.1.10
XT5.1.11
XT5.1.12
XT5.2.13
XT5.2.14
XT5.2.15
XT5.2.16
XT5.2.17
XT5.2.18
XT5.2.19
XT5.2.20
XT5.2.21
XT5.2.22
XT5.2.23
Installation and Commissioning
R1.CP/CS.B5
R1.CP/CS.C5
R1.CP/CS.D5
R1.CP/CS.A6
R1.CP/CS.B6
R1.CP/CS.C6
R1.CP/CS.D6
R1.CP/CS.A7
R1.CP/CS.B7
R1.CP/CS.C7
R1.CP/CS.D7
R1.CP/CS.A8
R1.CP/CS.B8
R1.CP/CS.C8
R1.CP/CS.D8
R1.CP/CS.A9
R1.CP/CS.B9
R1.CP/CS.C9
R1.CP/CS.D9
R1.CP/CS.A10
R1.CP/CS.B10
R1.CP/CS.C10
R1.CP/CS.D10
R3.CS.A
R3.CS.B
R3.CS.C
R3.CS.D
R3.CS.E
R3.CS.F
R3.CS.G
R3.CS.H
R3.CS.J
R3.CS.K
R3.CS.L
R3.CS.M
R3.CS.N
R3.CS.P
R3.CS.R
R3.CS.S
R3.CS.T
R3.CS.U
R3.CS.V
R3.CS.W
R3.CS.X
R3.CS.Y
R3.CS.Z
Connections on upper arm with CanBus.
R3.CP/CS
Air R1/2”
R3.CB
Figure 38 Customer connections on upper arm.
Signal name
Power supply
CPF
CPJ
52
Customer terminal Customer contact on Customer contact
controller,
manipulator base, R1 on upper arm, R3
see Figure 29
(cable not supplied)
XT6.1
XT6.2
R1.CP/CS.1
R1.CP/CS.2
R3.CP.F
R3.CP.J
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
CPK
CPL
CPM
XT6.3
XT6.4
XT6.5
R1.CP/CS.3
R1.CP/CS.4
R1.CP/CS.5
R3.CP.K
R3.CP.L
R3.CP.M
Signals
CSA
CSB
CSC
CSD
CSE
CSF
CSG
CSH
CSJ
CSK
CSL
CSM
XT5.1
XT5.2
XT5.3
XT5.3
XT5.5
XT5.6
XT5.7
XT5.8
XT5.9
XT5.10
XT5.11
XT5.12
R1.CP/CS.13
R1.CP/CS.14
R1.CP/CS.15
R1.CP/CS.16
R1.CP/CS.17
R1.CP/CS.18
R1.CP/CS.19
R1.CP/CS.20
R1.CP/CS.21
R1.CP/CS.22
R1.CP/CS.23
R1.CP/CS.24
R3.CS.A
R3.CS.B
R3.CS.C
R3.CS.D
R3.CS.E
R3.CS.F
R3.CS.G
R3.CS.H
R3.CS.J
R3.CS.K
R3.CS.L
R3.CS.M
R1.CB.1
R1.CB.2
R1.CB.3
R1.CB.4
R1.CB.5
R3.CB.1
R3.CB.2
R3.CB.3
R3.CB.4
R3.CB.5
CanBus
DRAIN
+24VCAN
0VCAN
CAN_H
CAN_L
3.15.3
Connection of signal lamp on upper arm (option)
Signal lamp
RH.3
-BK, +WH
Figure 39 Location of signal lamp.
Product Manual IRB 640
53
Connecting Signals
Installation and Commissioning
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.
3.16.2
Sensors
Sensors are connected to one optional digital unit.
Technical data
See Product Specification IRB 640, chapter 3.10.
The following sensors can be connected:
54
Sensor type
Signal level
Digital one bit sensors
High
Low
“1”
“0”
Digital two bit sensors
High
No signal
Low
Error status
“01”
“00”
“10”
“11” (stop program running)
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
3.16.3 Connection and address keying of the CAN-bus
Controller
Panel unit:
X9
CAN1
Back plane:
X10
X16
CAN3
CAN2
I/O unit
I/O unit
I/O unit
See Figure 41.
X9/X10/X16. 1
2
3
4
5
0V_CAN
CAN_L
drain
CAN_H
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 40 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.
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 41 CAN connections on back plane.
Product Manual IRB 640
55
Connecting Signals
Installation and Commissioning
DeviceNet Connector
Input and ID
12
1
56
Signal name
V- 0V
CAN_L
DRAIN
CAN_H
V+
GND
MAC ID 0
MAC ID 1
MAC ID 2
MAC ID 3
MAC ID 4
MAC ID 5
X5
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Description
Supply voltage GND
CAN signal low
Shield
CAN signal high
Supply voltage 24VDC
Logic GND
Board ID bit 0 (LSB)
Board ID bit 1
Board ID bit 2
Board ID bit 3
Board ID bit 4
Board ID bit 5 (MSB)
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
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 42.
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.
(0V)
1 2 3 4 5 6 7 8 9 10 11 12
X5 contact
address pins
address key
Example:
1
2
4
8
16
32
To obtain address 10:
cut off address pins 2 and 8, see figure.
To obtain address 25:
cut off address pins 1, 8 and 16.
Figure 42 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 640, 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 640
57
Connecting Signals
Installation and Commissioning
CONNECTION TABLE
Customer contacts: X1 - X4
Status LED’s
1
2
3
4
5
6
7
8
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
1
10
1
10
X4
1
10
10
1
12
X5
CAN-connection, see 3.16.3
X1
Unit function
Opto.
isol.
Signal name
Pin
X2
Customer conn.
Signal name
Pin
Out ch 1
1
Out ch 9
1
Out ch 2
2
Out ch 10
2
Out ch 3
3
Out ch 11
3
Out ch 4
4
Out ch 12
4
Out ch 5
5
Out ch 13
5
Out ch 6
6
Out ch 14
6
Out ch 7
7
Out ch 15
7
Out ch 8
8
Out ch 16
8
0V for out 1-8
9
0V
0V for out 9-16
9
24V for out 1-8
10*
24V
24V for out 9-16
10*
*)
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.
58
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
X3
Unit function
Opto.
isol.
Signal name
Pin
X4
Customer conn.
Signal name
Pin
In ch 9
1
In ch 1
1
In ch 2
2
In ch 10
2
In ch 3
3
In ch 11
3
In ch 4
4
In ch 12
4
In ch 5
5
In ch 13
5
In ch 6
6
In ch 14
6
In ch 7
7
In ch 15
7
In ch 8
8
In ch 16
8
0V for in 1-8
9
0V for in 9-16
9
Not used
10
Not used
10
24 V
0V
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to
ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100 Ω)
may be used.
Product Manual IRB 640
59
Connecting Signals
3.16.5
Installation and Commissioning
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 640, chapter 3.10.
Further information
For setup parameters, see User’s Guide, section System Parameters, Topic: Controller.
Circuit diagram, see chapter 11.
60
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
CONNECTION TABLE
Customer contacts: X1 - X4, X6
Status LED’s
1
2
3
4
5
6
7
8
OUT
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
IN
X2
1
10
1
X4
10
1
X6
1
10
16
1
10
1
12
X5
CAN-connection, see 3.16.3
X1
Unit function
Opto.
isol.
6
Signal name
Pin
X2
Customer conn.
Signal name
Pin
Out ch 1
1
Out ch 9
1
Out ch 2
2
Out ch 10
2
Out ch 3
3
Out ch 11
3
Out ch 4
4
Out ch 12
4
Out ch 5
5
Out ch 13
5
Out ch 6
6
Out ch 14
6
Out ch 7
7
Out ch 15
7
Out ch 8
8
Out ch 16
8
0V for out 1-8
9
0V
0V for out 9-16
9
24V for out 1-8
10*
24V
24V for out 9-16
10*
*)
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 640
61
Connecting Signals
Installation and Commissioning
X3
Unit function
Opto.
isol.
Signal name
Pin
X4
Customer conn.
Signal name
Pin
In ch 9
1
In ch 1
1
In ch 2
2
In ch 10
2
In ch 3
3
In ch 11
3
In ch 4
4
In ch 12
4
In ch 5
5
In ch 13
5
In ch 6
6
In ch 14
6
In ch 7
7
In ch 15
7
In ch 8
8
In ch 16
8
0V for in 1-8
9
0V for in 9-16
9
Not used
10
Not used
10
24 V
0V
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to
ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a serial resistor (100 Ω)
may be used.
X6
Signal name
62
Pin
Explanation
AN_ICH1
1
For test purpose only
AN_ICH2
2
For test purpose only
0V
3
0V for In 1-2
0VA
4
0V for Out 1-2
AN_OCH1
5
Out ch 1
AN_OCH2
6
Out ch 2
Product Manual IRB 640
Installation and Commissioning
3.16.6
Connecting Signals
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 640, 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 640
63
Connecting Signals
Installation and Commissioning
CONNECTION TABLE
Customer contacts: X1, X3, X 5 - X8
X8-Analog inputs
Bus staus LED’s
X7-Analog outputs
X8
X7
S2 S3
X2
X5 X3
Analog I/O
DSQC 355
X5-DiviceNet input
and ID connector
ABB flexible Automation
Not to be used
Figure 43 Analog I/O unit
Connector X5- DeviceNet connectors
See section 3.16.3 on page 55.
64
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
Connector X7 - Analog outputs
12
1
24
13
Product Manual IRB 640
Signal name
ANOUT_1
ANOUT_2
ANOUT_3
ANOUT_4
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
X7
Pin
1
2
3
4
5
6
7
8
9
10
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
GND
GND
GND
GND
GND
GND
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Description
Analog output 1, -10/+10V
Analog output 2, -10/+10V
Analog output 3, -10/+10V
Analog output 4, 4-20 mA
Analog output 1, 0 V
Analog output 2, 0 V
Analog output 3, 0 V
Analog output 4, 0 V
65
Connecting Signals
Installation and Commissioning
Connector X8 - Analog inputs
66
16
1
32
17
Signal name
ANIN_1
ANIN_2
ANIN_3
ANIN_4
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
+24V out
+24V out
+24V out
+24V out
+24V out
+24V out
+24V out
+24V out
GND
GND
GND
GND
GND
GND
GND
GND
X8
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Description
Analog input 1, -10/+10 V
Analog input 2, -10/+10 V
Analog input 3, -10/+10 V
Analog input 4, -10/+10 V
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
+24VDC supply
Analog input 1, 0V
Analog input 2, 0V
Analog input 3, 0V
Analog input 4, 0V
Product Manual IRB 640
Installation and Commissioning
3.16.7
Connecting Signals
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:
ABB Flexible Atomation
X20
Conveyor connection
X20
Encoder
CAN Rx
CAN Tx
MS
NS
POWER
X5
X5-DeviceNet input
and ID connector
DSQC 354
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
X3
X3
Not to be used
Device Net connector X5, see section 3.16.3 on page 55
Figure 44 Encoder unit, DSQC 354
Product Manual IRB 640
67
Connecting Signals
Installation and Commissioning
Encoder unit
24 V I/O
or external supply
0V
Encoder
Synch switch
1
2
24 V DC
3
0V
4
A
5
B
6
24 V DC
7
0V
8
9
10
11
12
10-16 not to be used
13
14
15
16
Opto
Opto
Opto
Opto
Opto
Opto
Galvanic
insulation
Figure 45 Encoder connections.
The wiring diagram in Figure 45 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.
68
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
Connector X20 - Encoder and digital input connections
Input and ID
1
16
Product Manual IRB 640
Signal name
24 VDC
0V
ENC
ENC
ENC_A
ENC_B
DIGIN
DIGIN
DIGIN
X20
Pin
1
2
3
4
5
6
7
8
9
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
Not to be used
10
11
12
13
14
15
16
Description
24 VDC supply
0V
Encoder 24 VDC
Encoder 0 V
Encoder Phase A
Encoder Phase B
Synch switch 24 VDC
0V
Synch switch digital input
69
Connecting Signals
3.16.8
Installation and Commissioning
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 640, 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
1
2
3
4
5
6
7
8
OUT
MS
IN
NS
OUT
9
10
11
12
13
14
15
16
IN
X1
X2
16
1
16
1
X3
X4
16
1
12
16
1
X5
70
1
CAN-connection, see 3.16.3
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
X1
Unit function
Signal name
Pin
X2
Customer conn.
Signal name
Pin
Out ch 9a
1
Out ch 1a
1
Out ch 1b
2
Out ch 9b
2
Out ch 2a
3
Out ch 10a
3
Out ch 2b
4
Out ch 10b
4
Out ch 3a
5
Out ch 11a
5
Out ch 3b
6
Out ch 11b
6
Out ch 4a
7
Out ch 12a
7
Out ch 4b
8
Out ch 12b
8
Out ch 5a
9
Out ch 13a
9
Out ch 5b
10
Out ch 13b
10
Out ch 6a
11
Out ch 14a
11
Out ch 6b
12
Out ch 14b
12
Out ch 7a
13
Out ch 15a
13
Out ch 7b
14
Out ch 15b
14
Out ch 8a
15
Out ch 16a
15
Out ch 8b
16
Out ch 16b
16
Product Manual IRB 640
supply
71
Connecting Signals
Installation and Commissioning
X3
Unit function
Opto.
isol.
Signal name
Pin
X4
Customer conn.
Signal name
Pin
In ch 9
1
In ch 1
1
In ch 2
2
In ch 10
2
In ch 3
3
In ch 11
3
In ch 4
4
In ch 12
4
In ch 5
5
In ch 13
5
In ch 6
6
In ch 14
6
In ch 7
7
In ch 15
7
In ch 8
8
In ch 16
8
0V for in 1-8
9
0V for in 9-16
9
Not used
10
Not used
10
Not used
11
Not used
11
Not used
12
Not used
12
Not used
13
Not used
13
Not used
14
Not used
14
Not used
15
Not used
15
Not used
16
Not used
16
24 V
0V
NOTE!
The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to
ground, to prevent disturbances, causes a short rush of current when setting the input.
When connecting a source (PLC), sensitive to pre-oscillation current, a serial resistor
(100 Ω) may be used.
72
Product Manual IRB 640
Installation and Commissioning
3.16.9
Connecting Signals
Digital 120 VAC I/O DSQC 320
Technical data
See Product Specification IRB 640, 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
1
2
3
4
5
6
7
8
OUT
OUT
MS
9
NS
IN
10
11
12
13
14
15
16
IN
X1
X2
16
1
16
1
X3
X4
16
1
12
16
1
X5
Product Manual IRB 640
1
CAN-connection, see 3.16.3
73
Connecting Signals
Installation and Commissioning
X1
Unit function
Opto
isol.
74
Signal name
Pin
X2
Customer conn.
Signal name
Pin
Out ch 9a
1
Out ch 1a
1
Out ch 1b
2
Out ch 9b
2
Out ch 2a
3
Out ch 10a
3
Out ch 2b
4
Out ch 10b
4
Out ch 3a
5
Out ch 11a
5
Out ch 3b
6
Out ch 11b
6
Out ch 4a
7
Out ch 12a
7
Out ch 4b
8
Out ch 12b
8
Out ch 5a
9
Out ch 13a
9
Out ch 5b
10
Out ch 13b
10
Out ch 6a
11
Out ch 14a
11
Out ch 6b
12
Out ch 14b
12
Out ch 7a
13
Out ch 15a
13
Out ch 7b
14
Out ch 15b
14
Out ch 8a
15
Out ch 16a
15
Out ch 8b
16
Out ch 16b
16
AC supply
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
X3
Unit function
Opto
isol.
Product Manual IRB 640
Signal name
Pin
X4
Customer conn.
Signal name
Pin
In ch 9a
1
In ch 9b
2
In ch 1a
1
In ch 1b
2
In ch 2a
3
In ch 10a
3
In ch 2b
4
In ch 10b
4
In ch 3a
5
In ch 11a
5
In ch 3b
6
In ch 11b
6
In ch 4a
7
In ch 12a
7
In ch 4b
8
In ch 12b
8
In ch 5a
9
In ch 13a
9
In ch 5b
10
In ch 13b
10
In ch 6a
11
In ch 14a
11
In ch 6b
12
In ch 14b
12
In ch 7a
13
In ch 15a
13
In ch 7b
14
In ch 15b
14
In ch 8a
15
In ch 16a
15
In ch 8b
16
In ch 16b
16
AC
N
75
Connecting Signals
Installation and Commissioning
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 640, 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
X8
Signal name
X9
Pin
Signal name
Pin
blue
1
Remote
I/O in
1
LINE2 (clear)
2
clear
2
shield
3
shield
3
cabinet ground
4
cabinet ground
4
X5
Device net input
and ID connector
Not to be used
Remote
I/O out
POWER
NS
MS
CAN Tx
CAN Rx
NAC STATUS
LINE1 (blue)
X5
X3
DSQC 350
X9
RIO out
X8
RIO in
ABB Flexible Atomation
Device Net connector X5, see section 3.16.3 on page 55
Figure 46 RIO-unit
76
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
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
Robot 1 - 128 in / 128 out
Quarter 1
Quarter 2
Robot 2 - 64 in / 64 out
Quarter 1
128 in / 128 out
Quarter 3
Quarter 4
Rack ID 12 (example)
Rack size 4
Starting quarter 1
64 in / 64 out
Other systems
Quarter 1
Quarter 2
Quarter 2
Rack ID 13 (example)
Rack size 2
Starting quarter 1
Quarter 3
Quarter 4
Robot 3 - 64 in / 64 out
Quarter 3
64 in / 64 out
Quarter 4
Rack ID 13 (example)
Rack size 2
Starting quarter 3
Figure 47 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 640
77
Connecting Signals
3.17.2
Installation and Commissioning
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.
ABB Flexible Atomation
X20
X21
Interbus-S
out
X21
RC
BA
RBDA
POWER
Interbus-S
CAN Rx
CAN Tx
MS
NS
POWER
X5
X5-DeviceNet input
and ID connector
DSQC 351
X20
Interbus-S
in
X3
X3
Interbus-S supply
Device Net connector X5, see section 3.16.3 on page 55
Figure 48 Interbus-S, DSQC 351
78
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
Communication concept
128 in/128 out
Master PLC
64 in/64 out
Robot 1
.3
Word 1.3
Robot 12
Word 4.7.7
Robot 32
Word 8.11
.11
IN
IN
IN
OUT
*1
OUT
OUT
*1
Figure 49 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
Product Manual IRB 640
Signal name
TPDO1
TPDI1
GND
NC
NC
TPDO1-N
TPDI1-N
NC
NC
X20
Pin
1
2
3
4
5
6
7
8
9
Description
Communication line TPDO1
Communication line TPDI1
Ground connection
Not connected
Not connected
Communication line TPDO1-N
Communication line TPDI1-N
Not connected
Not connected
79
Connecting Signals
Interbus-S OUT
5
1
9
6
Interbus-S supply
5
1
Installation and Commissioning
Signal name
TPDO2
TPDI2
GND
NC
+5V
TPDO2-N
TPDI2-N
NC
RBST
X21
Pin
1
2
3
4
5
6
7
8
9
Description
Communication line TPDO2
Communication line TPDI2
Ground connection
Not connected
+5VDC
Communication line TPDO2-N
Communication line TPDI2-N
Not connected
Synchronization
Signal name
0 V DC
NC
GND
NC
+ 24 V DC
X3
Pin
1
2
3
4
5
Description
External supply of Interbus-S
Not connected
Ground connection
Not connected
External supply of Interbus-S
NOTE! External supply is recommended to prevent loss of fieldbus at IRB power off.
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Installation and Commissioning
3.17.3
Connecting Signals
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
PROFIBUS ACTIVE
Profibus
NS
MS
CAN Tx
CAN Rx
POWER
X5
DSQC 352
X20
ABB Flexible Atomation
X20
Profibus
connection
X3
X5 - DeviceNet
connector
X3 - Power
connector
Figure 50 DSQC352, location of connectors
Communication concept
256 in/256 out
Master PLC
Robot 1
.3
Word 1:8
*1
Robot 11
.7
Word 9:16
128 in/128 out
2
Robot 2.11
Word 17:24
*1
Figure 51 Profibus-DP communication concept
Product Manual IRB 640
81
Connecting Signals
Installation and Commissioning
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
Profibus-DP supply
5
1
Signal name
Shield
NC
RxD/TxD-P
Control-P
GND
+ 5V DC
NC
Rxd/TxD-N
NC
X20
Pin
1
2
3
4
5
6
7
8
9
Signal name
0 V DC
NC
GND
NC
+ 24 V DC
X3
Pin
1
2
3
4
5
Description
Cable screen
Not connected
Receive/Transmit data P
Ground connection
Not connected
Recieve/Transmit data N
Not connected
Description
External supply of Profibus-DP
Not connected
Ground connection
Not connected
External supply of Profibus-DP
Device Net connector X5, see section 3.16.3 on page 55.
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Product Manual IRB 640
Installation and Commissioning
Connecting Signals
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 52).
The serial channels are:
- SIO1RS 232 with RTS-CTS-control and support for XON/XOFF,
transmission speed 300 - 19 200 baud.
- SIO2RS 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 640, chapter 3.10.
Separate documention is included.when the option RAP Seriel link is ordered.
External computer
Figure 52 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 640
83
Connecting Signals
Installation and Commissioning
DSCQ 330 (screw terminals)
X1
X2
Pin
Signal
Pin
Signal
1
TXD
1
TXD
2
RTS N
2
TXD N
3
0V
3
0V
4
RXD
4
RXD
5
CTS N
5
RXD N
6
0V
6
0V
7
DTR
7
DATA
8
DSR
8
DATA N
9
0V
9
0V
10
10
DCLK
11
11
DCLK N
12
12
0V
DSQC 369 (D-sub connectors)
X1
Pin
X2
Signal
1
Pin
Signal
1
TXD
2
RXD
2
TXD N
3
TXD
3
RXD
4
DTR
4
RXD N
5
0V
5
0V
6
DSR
6
DATA
7
RTS N
7
DATA N
8
CTS N
8
DCLK
9
DCLK N
9
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.
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Product Manual IRB 640
Installation and Commissioning
3.18.2
Connecting Signals
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. +70o 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...
LAN
TXD RXD
CAN
NS MS
A
U
I
X11 - AUI
connection
DSQC
336
F
T
P
E
X4 - TPE
connection
Ethernet HUB
C
O
N
S
O
L
E
Figure 53 Ethernet TCP/IP, outline diagram.
Product Manual IRB 640
85
Connecting Signals
Installation and Commissioning
Connector X4 - Ethernet TPE connector
Signal name
TPTX+
TPTXTPRX+
NC
NC
TPRXNC
NC
1
8
X4
Pin
1
2
3
4
5
6
7
8
Description
Transmit data line +
Transmit data line Receive data line +
Not connected
Not connected
Receive data line Not connected
Not connected
Connector X11 - Ethernet AUI connector
15
9
86
8
1
Signal name
GND
COLL+
TXD+
GND
RXD+
GND
NC
GND
COLLTXDGND
RXD+12V
GND
NC
X11
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Ground connection
Collision detection line +
Transmit data line +
Ground connection
Receive data line +
Ground connection
Not connected
Ground connection
Collision detection line Transmit data line Ground connection
Receive data line +12VDC
Ground connection
Not connected
Product Manual IRB 640
Installation and Commissioning
Connecting Signals
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.
M4 (x4)
M8 (x4)
45o
Required depth 200 mm
196
193
180 224 240
223
70
62
140
96
Holes for
flange
184
External panel enclosure
(not supplied)
200
Holes for
operator’s panel
100%
Holes for
teach pendant holder
Teach pendant
connection
Connection to
the controller
90
5 (x2)
155
Figure 54 Required preparation of external panel enclosure.
Product Manual IRB 640
87
Connecting Signals
88
Installation and Commissioning
Product Manual IRB 640
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
89
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
2.13.2.
4.2 Calibration of the manipulator
Calibrate the manipulator according to section 2.13.
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.
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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
Art. no.
Config id
Description
DSQC 345A
3HAB 8101-1
DC0
DC-link
DSQC 345B
3HAB 8101-2
DC1
DC-link
DSQC 345C
3HAB 8101-3
DC2
DC-link
DSQC 345D
3HAB 8101-4
DC3
DC-link, step down
DSQC 358C
3HAB 8101-10
DC2T
DC-link + single drive unit
DSQC 358E
3HAB 8101-12
DC2C
DC-link + single drive unit
For 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.
Product Manual IRB 2400
91
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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Product Manual IRB 2400
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
93
Installing the Control Program
94
Installation and Commissioning
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 640
95
External Axes
Installation and Commissioning
Measurement System 2
Drive System
1, inside
robot cabinet
alt.
Contains no
CPU
Drive System 2 inside
external axes cabinet
Drive System 2 inside
user designed cabinet
(non ABB drives)
Measurement
System 1
Figure 55 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 55. 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.
96
Product Manual IRB 640
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 640
97
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 56. Total of max 6 external axes can be installed.
.
Drive System 2
Atlas DMC
Atlas DMC
Atlas DMC
Atlas Copco
Atlas Copco
Atlas Copco
Mesurement
System 2
Serial measurement
board
Figure 56 Servo amplifier, DMC.
Atlas Copco Controls provides the information on suitable motors and how to make
installation and commissioning,
98
Product Manual IRB 640
Installation and Commissioning
5.3.2
External Axes
FBU
Atlas Copco Controls FBU (Field Bus Unit) can handle up to 3 external drive units, see
Figure 57.
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 57 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 640
99
External Axes
Installation and Commissioning
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 71.
MEASUREMENT SYSTEM 1
MEASUREMENT SYSTEM 2
configuration files MN4M1Dx
configuration files MNxM2Dx
CPU
Robot manipulator
Serial
Measurement
Board 1
6 resolvers
CPU
Measurement
System 1
serial
communication
Serial
Measurement
Board 2
node 4
1 resolver
Serial
Measurement
Board 1
Measurement
System 2
S
serial
communication
Serial
Measurement
Board 2
Serial
Measurement
Board 3
Max 6
resolvers
(5 if
one axis
connected to
Measurement
).
System
1)
Serial
Measurement
Board 4
Figure 58 Measurement systems.
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Product Manual IRB 640
Installation and Commissioning
External Axes
MEASUREMENT SYSTEM 1 (only external axes, no robot)
configuration files ACxM1D1
(Measurement System 2 may not be used
together with this configuration)
CPU
Measurement
System 1
serial
communication
Serial
Measurement
Board 1
Max 6
resolvers
Serial
Measurement
Board 2
Figure 59 Measurement system 1.
Resolver
Each resolver contains two stators and one rotor, connected as shown in Figure 60.
EXC*
0v EXC*
Stator X
Rotor
X*
0V X*
Stator Y
* See connection table
Y*
0V Y*
Figure 60 Connections for resolvers.
Technical data
Resolver
Integrated in motor of IRB type
or
art.no. 5766 388-5, size 11
Resolver must be approved by ABB
for reliable operation.
Motor to resolver gear ratio
1:1, direct drive
Resolver cable length:
Product Manual IRB 640
max 30 m (X, Y for each resolver)
total max 70 m for EXC signals.
101
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
102
Node 1
Node 2
Node 3
Node 4
Node 5
Node 6
EXC1
A1
A3
A5
0V
EXC1
A2
A4
A6
EXC2
A8
A10
A12
0V
EXC2
A9
A11
A13
X
B1
B3
B5
B8
B10
B12
Y
C1
C3
C5
C8
C10
C12
0V X
B2
B4
B6
B9
B11
B13
0V Y
C2
C4
C6
C9
C11
C13
Product Manual IRB 640
Installation and Commissioning
External Axes
Resolver, connectors on Measurement Board DSQC 313
R2.SMB
1-2
R2.SMB
1-4
R2.SMB
3-6
D-Sub 15 socket
D-Sub 25 pin
D-Sub 25 socket
GND
BATLD
0V
SDO-N
SDI-N
GND
0V EXC1
0V EXC1
Y2
X2
GND
X1
Y1
X2
Y2
GND
X4
Y4
X5
Y5
+BATSUP
+24V
SDO
SDI
Y1
X1
EXC1
EXC1
0V EXC1
0V EXC1
0V EXC1
X3
Y3
0V EXC2
0V EXC2
0V EXC2
X6
Y6
0V Y2
0V X2
0V Y1
0V X1
X4
Y4
0V EXC2
0V X1
0V Y1
X3
Y3
0V EXC1
0V X4
0V Y4
16
17
18
19
20
0V X2
0V Y2
EXC1
EXC1
EXC1
0V X5
0V Y5
EXC2
EXC2
EXC2
21
22
23
24
25
0V X3
0V Y3
0V X4
0V Y4
EXC2
0V X6
0V Y6
0V X3
0V Y3
EXC1
Contact/
point
R2.G
1
2
3
4
5
+BAT
0V BAT
R2.SMB
D-Sub 9 pin
6
7
8
9
10
11
12
13
14
15
Product Manual IRB 640
103
External Axes
Installation and Commissioning
R2.SMB
R2.SMB 1-4
R2.SMB 3-6
R2.SMB 1-2
R2.G
Serial Measurement Board (SMB)
SDO
SDI
+BAT
0V BAT
BATLD
BATSUP
+24 V
0V
5.3.4
serial communication output
serial communication input
battery +
battery 0 V
not to be used
not to be used
EXC1
24 V power
EXC2
0 V power
X1
excitation power to resolver 1,2,3
excitation power to resolver 4,5,6
Input x-stator node 1
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 connected using DMC:s and/or FBU:s. In section 5.3.5 there is a complete list of template
files for external controlled axes.
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Product Manual IRB 640
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 2
DRIVE SYSTEM 1
Drive System 1
serial communication
External
axis drive
system 1
(1 axis)
Unit number
Drive System 2
serial
communication
Robot
axes
0
3
2
1
Unit number
Transformer 1
0*
3*
2*
1*
External
axes drive
system 2
(5-6 axes)
Transformer 2
Figure 61 Drive systems with external cabinet.
Product Manual IRB 640
105
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
DC-link
(optional with driver inverter)
Drive System 1
serial communication
Drive unit
*
External
axis drive
system 1
(1 axis)
Unit number
Unit number for drive system 2
Robot
axes
0
0*
2
1
Transformer 1
External
axis drive
system 2
(2-3 axes)
Figure 62 Drive system installed in the S4C cabinet.
Technical data Drive System
Max
current
(A)
Rated
current
(A)
Max
bleeder
power
(kW)
Rated
bleeder
power
(kW)
Min
voltage
(V)
DSQC 345C / DC2
DSQC 358C / DC2T
DSQC 358E / DC2C
80
14.6
15.3
0.9
275
DSQC 345D / DC3
70
16.7
15.3
0.9
370
Figure 63 Rectifier units.
106
Product Manual IRB 640
Installation and Commissioning
External Axes
Unit type
Node 1
Node 2
Node 3
Total unit
DSQC 346A
3.25/1.6 A
3.25/1.6 A
1.5/1.0 D
8.0/4.2
DSQC 346B
6.7/3.2 B
3.25/1.6 A
1.5/1.0 D
11.45/5.8
DSQC 346C
11.3/5.3 C
11.3/5.3 C
6.7/4.0 B
29.3/12.1
DSQC 346G
29.7/16.5 G
36.8/20.0 T
66.5/30.0
DSQC 358C
36.8/20.0 T
36.8/20.0
DSQC 358E
11.3/5.3 C
11.3/5.3 C
Figure 64 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
111
- -3
- -3
- -3
222
WVU
- - W
- - V
- - U
WVU
Figure 65 Power connections, drive unit DSQC 346A, B, C
Pin
Node
Phase
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
111
111
222
222
222
UVW
UVW
UUU
VVV
WWW
Figure 66 Power connections, drive unit DSQC 246G
Pin
,Node
Phase
1 2 3
4 5 6
7 8 9
10 11 12
13 14 15
- - - - 222
222
222
- - - - UUU
VVV
WWW
Figure 67 Power connections, drive unit DSQC 358C, E
Product Manual IRB 640
X2
X2
X2
107
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.
Controller
XS7
R (U)
S (V)
T (W)
EXT PTC
0 V EXT PTC
Motor
PTC
0V EXT BRAKE
Brake
EXT BRAKE REL
EXT BRAKE PB
Manual brake
release
Figure 68 Connections of motor.
108
Product Manual IRB 640
Installation and Commissioning
External Axes
XS7, Connector on S4C robot cabinet wall (option: 391/392/394.)
Conn. Point
D
C
B
A
1
0V EXT PTC
M7 T
M7 S
M7 R
2
EXT PTC
M7 T
M7 S
M7 R
3
-
M7 T
M7 S
M7 R
4
PTC jumper 1
PTC jumper 2
LIM 2A
LIM 1A
5
PTC jumper 1
PTC jumper 2
LIM 2B
LIM 1B
6
M8 T
M8 S
M8 R
7
M8 T
M8 S
M8 R
8
BRAKE
REL
BRAKE
REL
9
0V BRAKE
BRAKE
REL
0V BRAKE
0V BRAKE
BRAKE PB
11
M9 T
M9 S
M9 R
12
M9 T
M9 S
M9 R
13
M9 T
M9 S
M9 R
10
-
14
15
16
Figure 69 Motor connections.
OPTION 391
M7
Drive system
1
Drive Unit Drive node Node type
0
2
T
OPTION 392
M7
M8
Drive system
2
2
Drive Unit Drive node Node type
0
2
T
0
1
G
OPTION 394
M7
M8
M9
Drive system
1
2
2
Drive Unit Drive node Node type
0
2
T
0
1
G
0
2
T
Product Manual IRB 640
109
External Axes
Installation and Commissioning
X7, Connector on external cabinet wall (options: 37x)
Conn. Point
D
C
B
A
1
0V EXT PTC
M7 T
M7 S
M7 R
2
EXT PTC
M7 T
M7 S
M7 R
3
-
M7 T
M7 S
M7 R
4
PTC jumper 1
PTC jumper 2
LIM 2A
LIM 1A
5
PTC jumper 1
PTC jumper 2
LIM 2B
LIM 1B
6
M10 R
M8 T
M8 S
M8 R
7
M10 R
M8 T
M8 S
M8 R
8
M10 S
M10 T
BRAKE
REL
BRAKE
REL
9
M10 S
M10 T
0V BRAKE
BRAKE
REL
10
-
0V BRAKE
0V BRAKE
BRAKE PB
11
M12 R
M9 T
M9 S
M9 R
12
M12R
M9 T
M9 S
M9 R
13
M12 S
M9 T
M9 S
M9 R
14
M12 S
M11 T
M11 S
M11 R
15
M12 T
M11 T
M11 S
M11 R
16
M12 T
M11 T
M11 S
M11 R
OPTION 37M : axes M7-M8
OPTION 37N : axes M7-M10
OPTION 37O : axes M7-M12
M7
M8
M9
M10
M11
M12
110
Drive systemDrive UnitDrive node Node type
2
1
2
T
2
1
1
G
2
2
2
T
2
2
1
G
2
3
2
T
2
3
1
G
Product Manual IRB 640
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
1
2
C
2
1
3
B
2
2
1
C
2
2
2
C
2
2
3
B
OPTION 37V : axes M7-M10
OPTION 37X : axes M7-M12
M7
M8
M9
M10
M11
M12
Drive systemDrive UnitDrive nodeNode type
2
1
1
C
2
1
2
C
2
2
2
T
2
2
1
G
2
3
2
T
2
3
1
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),
see Figure 70.
• External controlled external axis. File names ENxM2D2 (External Node x,
Measurement system 2, Drive system 2), see Figure 72.
• External axes files used in system without robot. File names ACxMyDz
(Axis Controlled x, Measurement system y, Drive system z), see Figure 71.
Product Manual IRB 640
111
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.
112
Product Manual IRB 640
Installation and Commissioning
Configuration file
Logical axis
External Axes
Measuring system
Drive system
System*
Node*
System*
Unit position
Node
MN4M1D1
7
1
4(7)**
1
0
2
MN4M1D2
7
1
4(7)**
2
1
2
MN4M1D12
7
1
4(7)**
2
0
2
MN1M2D1
8
2
1
1
0
2
MN1M2D2
8
2
1
2
1
1
MN1M2D12
8
2
1
2
0
1
MN2M2D1
9
2
2
1
0
2
MN2M2D2
9
2
2
2
2
2
MN2M2D12
9
2
2
2
0
2
MN3M2D1
10
2
3
1
0
2
MN3M2D2
10
2
3
2
2
1
MN3M2D12
10
2
3
2
0
1
MN4M2D1
11
2
4
1
0
2
MN4M2D2
11
2
4
2
3
2
MN4M2D12
11
2
4
2
0
2
MN5M2D1
12
2
5
1
0
2
MN5M2D2
12
2
5
2
3
1
MN5M2D12
12
2
5
2
0
1
MN6M2D1
7
2
6
1
0
2
MN6M2D2
7
2
6
2
1
2
MN6M2D12
7
2
6
2
0
2
Figure 70 Configuration files with default data.
Product Manual IRB 640
113
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
System*
Node*
System*
Unit position
Node
AC1M1D1
7
1
1
1
1
2
AC2M1D1
8
1
2
1
2
2
AC3M1D1
9
1
3
1
3
2
AC4M1D1
10
1
4
1
2
1
AC5M1D1
11
1
5
1
3
1
AC6M1D1
12
1
6
1
1
1
Figure 71 Configuration files with default data.
Configuration file
Logical
axis
Measuring system
Drive system
System*
Node*
System*
Unit position
Node
EN1M2D2
8
2
1
2
0
1
EN2M2D2
9
2
2
2
1
1
EN3M2D2
10
2
3
2
2
1
EN4M2D2
11
2
4
2
3
1
EN5M2D2
12
2
5
2
4
1
EN6M2D2
13
12
6
2
5
1
Figure 72 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.
114
Product Manual IRB 640
Maintenance
CONTENTS
Page
1 Maintenance Schedule............................................................................................. 4
1.1 Maintenance intervals for gear axes 1 and 6................................................... 5
1.2 Approx. estimate of operating life of base cable ............................................ 6
2 Instructions for Maintenance ................................................................................. 7
2.1 General instructions for the manipulator ........................................................ 7
2.2 Checking the oil and grease levels.................................................................. 7
2.3 Lubricating the large diameter bearing, axis 1................................................ 8
2.4 Lubricating gear box, axis 1............................................................................ 9
2.5 Inspect and lubricate the bearings, balancing units axis 2 .............................. 10
2.6 Lubricating piston rod, balancing unit axis 2.................................................. 11
2.7 Lubricating gearboxes, axes 2 and 3............................................................... 12
2.8 Lubricating gear box, axis 6............................................................................ 13
2.9 Checking mechanical stop, axis 1 ................................................................... 14
2.10 Changing the battery in the measuring system ............................................. 15
2.11 Changing filter/cooling of motor axis 1 ........................................................ 16
2.12 Changing filters/vacuum cleaning the drive-system cooling........................ 17
2.13 Changing the battery for memory back-up ................................................... 17
2.14 RAM Battery lifetime ................................................................................... 18
Product Manual IRB 640
1
Maintenance
CONTENTS
Page
2
Product Manual IRB 640
Maintenance
Maintenance
The robot is designed to be able to work under very demanding conditions with a
minimum of maintenance. Nevertheless, certain routine checks and preventative
maintenance must be carried out at specified periodic intervals, as shown in the table
below.
• 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 a normal working environment. In very dusty environments, however,
the interior of the cabinet should be inspected at regular intervals. Use a vacuum
cleaner if necessary. Change filters in accordance with prescribed maintenance
procedures.
• Check that the sealing joints and cable glands are really airtight so that dust and
dirt are not sucked into the cabinet.
Product Manual IRB 640
3
Maintenance
1 Maintenance Schedule
Maintenance
intervals
Prescribed maintenance
MANIPULATOR
Check
twice a
year
Check
once a
year
4 000 h
or
2 years
Balancing unit axis 2
Bearings, inspection
X
Balancing unit axis 2
Bearings, greasing
X
Large diameter bearing
Greasing
X
Cabling
X2
Mechanical stop axis 1
X3
Gearboxes 1, 2, 3, 6
Grease changing
X4
Friction washer
X5
Accumulator for measuring system
Exchange
3 years6
Cooling motor, axis 1
Filter changing
X7
X
Filter for drive-system cooling
X7
X
Memory back-up
Battery changing
5 years
X1
Balancing unit axis 2
Piston rod/Guiding ring
CONTROL
SYSTEM
12 000 h
or
3 years
X8
1. If the robot operation is utilized in adverse conditions (for example: particle-laden environments, such as
spot welding, grinding, deflashing, etc.), perform preventive maintenance more frequently to ensure
proper reliability of the robot system. See section 2.6.
2. Inspect all visible cabling. Change if damaged. See section 1.2.
3. Check the mechanical stop devices for deformation and damage. If the stop pin or the adjustable stop arm
is bent, it must be replaced. See section 2.9.
4. Also see section 1.1 regarding axis 1.
5. See Spare Parts, section 1.1, item 205.32.
6. See section 2.10.
7. Change interval is strongly dependent on the environment around the robot. See section 2.11 and 2.12.
8. See section 2.14.
4
Product Manual IRB 640
Maintenance
1.1 Maintenance intervals for gear axes 1 and 6
Axis 1
Operation (h)
13 000
12 000
11 000
10 000
9 000
8 000
3
4
5
6
Cycle time (s)
Figure 1 Recommended interval for grease exchange axis 1.
Life time (operation) (h)
40 000
30 000
20 000
10 000
0
3
4
5
6
Cycle time (s)
Figure 2 Approx. estimate of operating life of gearbox axis 1 as a function of the cycle time.
Product Manual IRB 640
5
Maintenance
Axis 6
Operation (h)
12 000
11 000
10 000
9 000
8 000
7 000
6 000
5 000
4 000
50
100
Moment of
inertia Ja6 (kgm2)
120
Figure 3 Recommended interval for grease exchange axis 6
Life time (operation) (h)
40 000
30 000
20 000
10 000
50
100
120
Moment of
inertia Ja6 (kgm2)
Figure 4 Approx. estimate of operating life of gearbox axis 6 as a function of the moment of
inertia Ja6. Ja6 according to the Product Specification, chapter 3.
1.2 Approx. estimate of operating life of base cable
Approx. estimate of operating life of base cable is 4 million cycles.
6
Product Manual IRB 640
Maintenance
2 Instructions for Maintenance
2.1 General instructions for the manipulator
Check regularly:
• for any oil leaks. If a major oil leak is discovered, call for service personnel.
• for excessive play in gears. If play develops, call for service personnel.
• that the cabling between the control cabinet and robot is not damaged.
Cleaning:
• Clean the robot exterior with a cloth when necessary. Do not use aggressive solvents
which may damage paint or cabling.
2.2 Checking the oil and grease levels
Axes 1, 2, 3 and 6
The level in the gearboxes is checked by adding new grease, until grease comes out
through the special draining holes. See Chapter 2.7, Lubricating gearboxes, axes 2 and
3 and Chapter 2.8, Lubricating gear box, axis 6.
Product Manual IRB 640
7
Maintenance
2.3 Lubricating the large diameter bearing, axis 1
• Remove the two plugs.
• Fit the grease nipples (R1/8” art. No. 2545 2021-26).
• Grease through (1) the two nipples. Turn the axis 1 +90o while greasing is in progress.
• Continue greasing until new grease exudes from the rubber seal (2).
1
A-A
2
A-A
A-A
Figure 5 Lubricating the large diameter bearing.
• Remove excess grease with a cloth.
Type of grease:
- ABB art. no. 1171 4013-301, quality 7 1401-301
- ESSO Beacon EP 2
- Shell Alvanina EP Grease
- SKF Grease LGEP 2
- BP Energrease LS-EP 2.
Tools:
- See Tool List.
8
Product Manual IRB 640
Maintenance
2.4 Lubricating gear box, axis 1
• Remove the cover on the base (4), see Figure 6.
• Remove the plug (3).
• Fit an R1/2” grease nipple and drain tube.
• Grease through the nipple (1).
• Continue greasing until new grease exudes from the drain tube. See Volume below.
• Axis 1 should be slowly moved backwards and forwards while greasing.
• Suck out any excess grease before replacing the plug.
Volume:
- 1.3 litres (0.36 US gallon)
- About 3.0 litres (0.82 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAC 2331-1
Molywhite RE No 00
Tools:
- See Tool list.
4
2
3
1
Figure 6 Lubricating axis 1.
Product Manual IRB 640
9
Maintenance
2.5 Inspect and lubricate the bearings, balancing units axis 2
The bearings should be inspected and lubricated every 12 000 hours.
1. Move axis 2 to the sync position.
Make sure the shaft between the upper and lower arms does not rotate when
unscrewing the KM nut.
2. Remove the KM- nuts (KM-8), the outer support washers and sealing rings.
Inspect
3. Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft
3HAB 6558-1, lower: aux. shaft 3HAB 6567-1). The shafts should be tightened to
their bottom position.
4. Off-load the bearings using an M10x50 screw at the cylinder top.
5. Put out the cylinder so that the inner rings are fully exposed. Wipe the inner rings
clean and check that there are no pressure marks or other similar deformations.
It is quite normal for the bearing races to have a darker colour than the surrounding
material.
6. Inspect the support washers and sealing rings.
7. Push in the cylinder, make sure the inner support washers and sealing rings gets in
correct position.
8. Remove the auxiliary shafts.
Lubrication
8. Fit the lubricating tool 3HAC 4701-1. The tool should be tightened to the bottom
position only by hand power.
9. Grease through the nipple. Continue greasing until the grease excudes behind the
inner sealing ring. Repeat procedure for the other bearings.
10. Remove the lubricating tool and clean the threads on the shaft ends free from
grease.
11. Remount the outer sealing rings, apply some grease on the support washers, apply
Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque
of 50-60 Nm.
12. Chek play (min 0.1 mm) between support washer and bearingseat at both bearings.
13. N.B. Remove the M10x50 screw.
For more information about the procedure of replacing bearings, see Repairs.
10
Product Manual IRB 640
Maintenance
Type of grease
- ABB art no. 1171 4013-301, quality 7 1401-301.
- ESSO Beacon EP 2.
- Shell Alvanina EP Grease.
- SKF Grease LGEP 2.
- BP Energrease LS-EP2.
2.6 Lubricating piston rod, balancing unit axis 2
Move axis 2 to a position where the balancing units are in the horizontal position.
Wear
Check the guiding ring for wear. If there is a risk of metallic contact between the piston
rod and the end cover, the guiding ring must be replaced. For replacement, see Repairs.
The article number of the guiding ring is 3HAB 6176-1.
Lubrication
The piston rods should be lubricated. Clean the piston rod and apply new grease when
necessary.
Type of grease
- Castrol Spheerol SX2 or equivalent.
- Shell Grease 1352 CA EP2.
- OK Super Grease L2.
- Statoil Uniway 2X2N.
Product Manual IRB 640
11
Maintenance
2.7 Lubricating gearboxes, axes 2 and 3
• Remove the filler (1) and drain (2) plugs. See Figure 7.
• Grease through the filling hole (1).
• The axes 2 and 3 must be moved slowly backwards and forwards several times while
greasing.
• Continue greasing until new grease exudes from the drain hole (2). See Volume below.
• Move the axes backwards and forwards a couple of times before the plugs are
replaced, so that excess grease is pressed out. This is to prevent over-pressure in the
gearbox with risks for leakage.
Volume:
- 1.2 litres (0.33 US gallon).
- About 2.0 litres (0.82 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAC 2331-1
Molywhite RE No 00
Tools: See Tool list.
WARNING! It is important that the drain plug is removed during lubrication.
1
2
Figure 7 Drain holes, axes 2 and 3.
12
Product Manual IRB 640
Maintenance
2.8 Lubricating gear box, axis 6
• Remove the plug from the drain hole (1). See Figure 8
WARNING! It is important that the drain plug is removed.
• Grease through the radial nipple of the turning gear (2).
• Rotate axis 6 while greasing.
• Continue to grease until new grease exudes from the drain hole (1). See Volume
below.
Move axis 6 backwards and forwards a couple of times before the plugs are replaced,
so that excess grease is pressed out. This is to prevent over-pressure in the gearbox,
with risks for leakage.
Volume:
- 0.30 litres (0.085 US gallon).
- About 0.4 litres (0.11 US gallon) should be used when changing the grease.
Type of grease:
- ABB 3HAC 2331-1
Guide hole
Molywhite RE No 00
13o
2
1
Figure 8 Greasing axis 6.
Product Manual IRB 640
13
Maintenance
2.9 Checking mechanical stop, axis 1
Check regularly, as follows:
Fixed stop arm:
- that the arm is not bent.
Stop pin:
- that the rubber cover is not damaged
- that the stop pin can move in both directions
- that the stop pin is not bent.
Adjustable stop arms:
- that the arms are not bent.
WARNING!
1. If the fixed stop arm is bent, no attempt must be made to straightened it.
2. If the pin is bent, a collision between the swinging stop arm and the stop pin has
probably occurred. A bent stop pin must always be replaced by a new one.
3. If any of the adjustable stop arms are bent, they must be replaced by new ones.
Article number
14
Stop pin
3HAB 4082-1
Adjustable stop arm
3HAB 4533-3 (Option)
Product Manual IRB 640
Maintenance
2.10 Changing the battery in the measuring system
The battery to be replaced is located under the cover, in the front of the frame.
(See Figure 9).
The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4.
The battery must never be 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 change.)
• Loosen the battery terminals from the serial measuring board and cut the clasps that
keep the battery unit in place.
• Install a new battery with two clasps and connect the terminals to the serial measuring
board.
• The Ni-Cd battery takes 36 hours to recharge; the mains supply must be switched on
during this time and there must not be any interruptions in the power supply.
Figure 9 The battery is located in the front of the frame.
Alternative battery
As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed.
The lithium battery needs no charging and for this reason there is a blocking diode
which prevents charging from the serial measurement board.
The benefit with a lithium battery is the extended service life, which can be up to 5
years, compared with a Ni-Cd battery’s max service life of 3 years.
Two types of lithium battery are available:
- a 3-cell battery, art.no. 3HAB 9999-1
- a 6-cell battery, art.no. 3HAB 9999-2
Product Manual IRB 640
15
Maintenance
The service life of the lithium battery depends on how frequently the user switches off
the power. The estimated max service life in years for the different types of lithium
battery and the recommended exchange intervals are shown below:
User type:
Exchange 3-cell:
Exchange 6-cell:
1. Vacation (4 weeks) power off
every 5 years
every 5 years*
2. Weekend power off + user type 1
every 2 years
every 4 years
3. Nightly power off + user types 1 and 2
every year
every 2 years
* Because of material ageing the maximum service life is 5 years.
Voltage of batteries, measured at power off:
Min.
Max.
Ni-Cd
7.0 V
8.7 V
Lithium
7.0 V
-
The battery is exchanged as described in the first section of this chapter, except for the
fastening of the 3-cell battery on the board, see Figure 10.
Clasps
Connect the clasps
together
N.B.
Tighten the band around
the batteries before
tightening the clasps.
Figure 10 Fastening of the 3-cell battery.
2.11 Changing filter/cooling of motor axis 1
• Loosen the filter holder at the intake. Insert the new filter and replace the filter holder.
The article number of the filter is 3HAA 1001-612.
16
Product Manual IRB 640
Maintenance
2.12 Changing filters/vacuum cleaning the drive-system cooling
The article number of the filter is 3HAC 0927-1.
• 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.
2.13 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 (see Figure 11).
.
Plan view
Front view
Warning:
Warning:
• Do not charge the batteries. An explosion could
result or the cells could overheat.
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.
• 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.
Figure 11 The location of the batteries.
Product Manual IRB 640
17
Maintenance
• 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 kept on. Otherwise, all
the memory contents will be erased. A completely new installation of Robot Ware and
parameters is then necessary, see Installation and Commissioning.
2.14 RAM Battery lifetime
The maximum service life of the lithium 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
First battery
Both batteries
4 MB
6
12
6 MB
5
10
8 MB
6.5
13
16 MB
5
10
A battery test is performed during the following occasions:
1. System diagnistics (before softeware 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.
18
Product Manual IRB 640
Troubleshooting Tools
CONTENTS
Page
1 Diagnostics................................................................................................................
1.1 Tests ................................................................................................................
1.2 Monitor Mode 2 ..............................................................................................
1.2.1 Entering the test mode from the teach pendant ...................................
1.2.2 Console connected to a PC ..................................................................
3
5
6
7
7
2 Indication LEDs on the Various Units ................................................................... 14
2.1 Location of units in the cabinet....................................................................... 14
2.2 Robot computer DSQC 363/373 ..................................................................... 14
2.3 Main computer DSQC 361 ............................................................................. 15
2.4 Memory board DSQC 324/16Mb, 323/8Mb, 317/6 Mb, 321/4MB................ 15
2.5 Ethernet DSQC 336 ........................................................................................ 16
2.6 Power supply units .......................................................................................... 17
2.7 Panel unit DSQC 331...................................................................................... 19
2.8 Digital and Combi I/O units............................................................................ 20
2.9 Analog I/O, DSQC 355................................................................................... 21
2.10 Remote I/O DSQC 350, Allen Bradley......................................................... 22
2.11 Interbus-S, slave DSQC 351 ......................................................................... 23
2.12 Profibus-DP, DSQC352 ................................................................................ 24
2.13 Encoder unit, DSQC354 ............................................................................... 25
2.14 Status LEDs description................................................................................ 27
3 Measuring Points ..................................................................................................... 30
3.1 Back plane....................................................................................................... 30
3.2 Signal description, RS 232 and RS 485 .......................................................... 31
3.3 X1 and X2 Serial links: SIO 1 and SIO 2 ....................................................... 33
3.4 X9 Maintenance plug ...................................................................................... 34
3.4.1 Power supply ....................................................................................... 34
3.4.2 X9 VBATT 1 and 2 ............................................................................. 35
3.4.3 Drive system........................................................................................ 35
3.4.4 Measuring system................................................................................ 36
3.4.5 Disk drive ............................................................................................ 37
3.4.6 Teach pendant...................................................................................... 38
3.4.7 CAN..................................................................................................... 39
3.4.8 Safety................................................................................................... 39
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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.
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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
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
I/O
COMPUTER
System in operation
Set flag for warm start
MAIN
COMPUTER
4
Operating
mode
Service
mode
Reset
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.
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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
Signal
Description
2
RXD
Serial receive data
3
TXD
Serial transmit data
5
GND
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:
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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
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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
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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
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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
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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
Optional board
Optional board
Transformer
Main computer
Supply
unit
Memory board
Robot computer
Drive unit 1
Drive unit 2
Drive unit 3
DC link
2.1 Location of units in the cabinet
IRB 1400
IRB 2400
IRB 4400
IRB 6400
IRB 640
IRB 840/A
IRB 340
Axes
Axes
Axes
Axes
Axes
Axes
Axes
1
1, 2, 4
1, 2, 4
1, 6
1, 6
1, 6
1(X), 6(C)
2, 1
2
3, 5, 6
3, 5, 6
2, 4
2, 4
2, 3
2(Y), 3(Z)
(4), 3
3, 5
3, 5
Drive unit
3
2.2 Robot computer DSQC 363/373
SIO1
TxD RxD
Designation
Colour
Description/Remedy
F
Red
Turns off when the board approves the
initialisation.
TxD
Yellow
See section 2.14.
RxD
Yellow
See section 2.14.
NS
Green/red
See section 2.14.
MS
Green/red
See section 2.14.
SIO2
TxD RxD
CAN
NS MS
DSQC
322
F
C
O
N
S
O
L
E
14
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Troubleshooting Tools
2.3 Main computer DSQC 361
Designation
Colour
Description/Remedy
F
Red
Turns off when the board approves the
initialisation.
DSQC
361
F
2.4 Memory board DSQC 324/16Mb, 323/8Mb
Designation
F
Colour
Description/Remedy
Red
Turns off when the board approves the
initialisation.
DSQC
3xx
F
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15
Troubleshooting Tools
2.5 Ethernet DSQC 336
Designation
Colour
Description/Remedy
TxD
Yellow
Indicates data transmit activity.
If no light when transmission is
expected, check error messages and
check also system boards in rack.
RxD
Yellow
Indicates data receive activity.
If no light, check network and
connections.
NS
Green/red
See section 2.14.
MS
Green/red
See section 2.14.
F
Red
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.
LAN
TXD RXD
CAN
NS MS
A
U
I
DSQC
336
F
T
P
E
C
O
N
S
O
L
E
16
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Troubleshooting Tools
2.6 Power supply units
DSQC 334
X1
X5
AC OK
X2
X3
Designation
Colour
Description/Remedy
AC OK
Green
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.
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Troubleshooting Tools
X1
X3
X5
AC OK
24 V I/O
X7
Only
DSQC 365
X2
18
Designation
Colour
Description/Remedy
AC OK
Green
3 x 55V supply OK
(start of ENABLE chain)
24 V I/O
Green
24 V I/O OK
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Troubleshooting Tools
2.7 Panel unit DSQC 331
WARNING!
REMOVE JUMPERS BEFORE CONNECTING
ANY EXTERNAL EQUIPMENT
EN
MS NS
ES1 ES2 GS1 GS2 AS1 AS2
Status LED’s
Product Manual
Designation
Colour
Description/Remedy
EN
Green
Enable signal from power supply
and computers
MS/NS
Green/red
See section 2.14.
ES1 and 2
Yellow
Emergency stop chain 1 and 2 closed
GS1 and 2
Yellow
General stop switch chain 1 and 2 closed
AS1 and 2
Yellow
Auto stop switch chain 1 and 2 closed
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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
MS
IN
NS
X1
X3
OUT
9
10
11
12
13
14
15
16
IN
X2
1
1
10
1
10
X4
1
10
10
1
12
X5
20
Designation
Colour
Description/Remedy
IN
Yellow
Lights at high signal on an input.
The higher the applied voltage, the
brighter the LED will shine. This
means that even if the input voltage
is just under the voltage level “1”,
the LED will glow dimly.
OUT
Yellow
Lights at high signal on an output.
The higher the applied voltage, the
brighter the LED will shine.
MS/NS
Green/red
See section 2.14.
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Troubleshooting Tools
2.9 Analog I/O, DSQC 355
Bus status LED’s
Bus staus LED’s
X8
X7
S2 S3
X2
X5 X3
MS
Analog I/O
DSQC 355
N.U
RS232 Rx
CAN Rx
+5V
+12V
N.U
RS232 Tx
CAN Tx
-12V
NS
ABB flexible Automation
Designation
Colour
Description/Remedy
NS/MS
Green/red
See section 2.14.
RS232 Rx
Green
Indicates the state of the RS232 Rx line.
LED is active when receiving data.
If no light, check communication line and connections.
RS232 Tx
Green
Indicates the state of the RS232 Tx line.
LED is active when tranceiving data.
If no light when transmission is expected, check
error messages and check also system boards in
rack.
Green
Indicates that supply voltage is present and at
correct level.
Check that voltage is present on power unit.
Check that power is present in power connector.
If not, check cables and connectors.
If power is applied to unit but unit does not
work, replace the unit.
+5VDC / +12VDC /
-12VDC
Product Manual
21
Troubleshooting Tools
2.10 Remote I/O DSQC 350, Allen Bradley
POWER
NS
MS
CAN Tx
CAN Rx
NAC STATUS
Bus status LED’s
POWER
NS
MS
CAN Tx
CAN Rx
X5
X9
X3
22
X8
DSQC 350
NAC STATUS
ABB Flexible Atomation
Designation
Colour
Description/Remedy
POWER-24 VDC
Green
Indicates that a supply voltage is
present, and has a level above 12 VDC.
If no light, check that voltage is present on
power unit. That power is present in power
connector. If not, check cables and connectors.
If power is applied to unit but unit does not
work, replace unit.
NS/MS
Green/red
See section 2.14.
CAN Tx/CAN Rx Yellow
See section 2.14.
NAC STATUS
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
Green
Product Manual
Troubleshooting Tools
2.11 Interbus-S, slave DSQC 351
X21
RC
BA
RBDA
POWER
Interbus-S
CAN Rx
CAN Tx
MS
NS
POWER
X5
Product Manual
DSQC 351
X20
ABB Flexible Automation
Bus status LED’s
POWER
NS
MS
CAN Tx
CAN Rx
POWER
RBDA
BA
RC
X3
Designation
Colour
Description/Remedy
POWER-24 VDC
Green
Indicates that a supply voltage is present,
and has a level above 12 VDC.
NS/MS
Green/red See section 2.14.
CAN Tx/CAN Rx
Green/red See section 2.14.
POWER- 5 VDC
Green
Lit when both 5 VDC supplies are within
limits, and no reset is active.
RBDA
Red
Lit when this Interbus-S station is last
in the Interbus-S network.
If not as required, check parameter setup.
BA
Green
Lit when Interbus-S is active.
If no light, check network, nodes and
connections
RC
Green
Lit when Interbus-S communication
runs without errors.
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Troubleshooting Tools
PROFIBUS ACTIVE
Profibus
NS
MS
CAN Tx
CAN Rx
POWER
X5
Bus status LED’s
Profibus active
NS
MS
CAN Tx
CAN Rx
DSQC 352
X20
ABB Flexible Automation
2.12 Profibus-DP, DSQC352
Power
X3
Designation
Colour
Description/Remedy
Profibus active
with
Green
Lit when the node is communicating
the master. If no light, check system
messages in robot and in Profibus net.
24
NS/MS
Green/red See section 2.14.
CAN Tx/CAN Rx
Green/red See section 2.14.
POWER, 24 VDC
Green
Indicates that a supply voltage is
present, and has a level above 12 VDC.
If no light, check that voltage is present
in power unit.Check that power is
present in the power connector. If not,
check cables and connectors. If power
is available at the unit but the unit does
not function, replace the unit
Product Manual
Troubleshooting Tools
2.13 Encoder interface unit, DSQC354
ABB Flexible Automation
Status LED’s
X20
Encoder
CAN Rx
CAN Tx
MS
NS
POWER
X5
Product Manual
ENC 1A
ENC 1B
DIGIN 1
DSQC 354
Digin 2
Enc 2B
Enc 2A
Digin 1
Enc 1B
Enc 1A
POWER
NS
MS
CAN Tx
CAN Rx
X3
Designation
Colour
Description/Remedy
POWER, 24 VDC
Green
Indicates that a supply voltage is
present, and has a level above 12 VDC.
If no light, check that voltage is present on
power unit. That power is present in
connector X20. If not, check cables and
connectors.If power is applied to unit but
unit does not work, replace unit.
NS/MS
Green/red
See section 2.14.
CAN Tx/CAN Rx
Yellow
See section 2.14.
ENC 1A/1B
Green
Indicates phase 1 and 2 from encoder.
Flashes by each Encoder pulse.
By frequencies higher than a few Hz,
flashing can no longer be observed (light
will appear weaker).
If no light, faulty power supply for input
circuit (internal or external). Defective
input circuit on board. External wiring or
connectors, short circuit or broken wire.
Internal error in unit. Constant light 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
26
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.
Product Manual
Troubleshooting Tools
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
MS - Module status
NS - Network status
Some units:
CAN Tx - CAN network transmit
CAN Rx - CAN network receive
MS - Module status
This bicolour (green/red) LED provides device status. It indicates whether or not the device
has power and is operating properly. The LED is controlled by software. The table below
shows the different states of the MS LED.
Description
Remedy / Source of fault
Off
No power applied to the device.
Check power supply.
Green
If no light, check other LED modes.
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.
Check system parameters.
Check messages.
Flashing red
Recoverable minor fault.
Check messages.
Red
The device has an unrecoverable fault.
Device may need replacing.
Flashing red/green
The device is running self test.
If flashing for more than a few seconds,
check hardware.
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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.
28
Description
Remedy / Source of fault
Off
Device has no power or is not on-line.
The device has not completed the
Dup_MAC_ID test yet.
Check status of MS LED.
Check power to affected module.
Flashing green
Device is on-line, but has no connections
in the established state.
The device has passed the Dup_MAC_ID
test, is on-line, but has no established
connections to other nodes.
For a group 2 only device it means that
the device is not allocated to a master.
For a UCMM capable device it means
that the device has no established
connections.
Check that other nodes in network are
operative.
Check parameter to see if module has
correct ID.
Green
The device is on-line and has connection
in the established state.
For a group 2 only device it means that
the device is allocated to a master.
For a UCMM capable device it means
that the device has one or more
established connections.
If no light, check other LED modes.
Flashing red
One or more I/O connections are in the
Time-Out state.
Check system messages.
Red
Failed communication device. The device
has detected an error that has rendered it
incapable of communicating on the
network.
(Duplicate MAC_ID, or Bus-off).
Check system messages and parameters.
Product Manual
Troubleshooting Tools
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
Remedy / Source of fault
Green LED. Physically connected to the
Can Tx line. Flashes when the CPU is
receiving data on the CAN bus.
If no light when transmission is expected,
check error messages.
Check system boards in rack.
CAN Rx - CAN network receive
Description
Remedy / Source of fault
Green LED. Physically connected to the
Can Rx line. Flashes when the CPU is
transmitting data on the Can bus.
If no light, check network and
connections.
Product Manual
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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.
Serial ports
SIO 1 RS 232
SIO2 RS 422
Battery
1
2
Test points X5-X8
Maintenance
plug, X9
CAN3 (ext. I/O)
CAN2 (manip. I/O)
CAN1 (panel unit)
Drive units,
X14 (ext. axes)
Serial meas.
board 2, X12
(ext. axes)
Disk drive
- data
- supply
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 supply
Power contact can also be
a 15-pole contact,
both variant will exsist
Figure 1 Back plane
30
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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
0V
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
5V
5V
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
X1
X2
Pin
Signal
Pin
Signal
1
TXD
1
TXD
2
RTS N
2
TXD N
3
0V
3
0V
4
RXD
4
RXD
5
CTS N
5
RXD N
6
0V
6
0V
7
DTR
7
DATA
8
DSR
8
DATA N
9
0V
9
0V
10
10
DCLK
11
11
DCLK N
12
12
0V
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Troubleshooting Tools
D-sub connector
X1
Pin
X2
Signal
1
Pin
Signal
1
TXD
2
RXD
2
TXD N
3
TXD
3
RXD
4
DTR
4
RXD N
5
0V
5
0V
6
DSR
6
DATA
7
RTS N
7
DATA N
8
CTS N
8
DCLK
9
DCLK N
9
3.4 X9 Maintenance plug
3.4.1 Power supply
Supply voltages can be measured at the following points:
X9
Pin
Row A
Row C
28
ACOK
DCOK
29
+ 5V_TST
0V
30
+ 15V_TST
0V
31
15V_TST
0V
32
+ 24V_TST
0V
There is a 10 kΩ 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
Row A
Row C
7
VBATT1
VBATT2
8
0V
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).
X9
Pin
A
C
16
DRCI1
DRCI1 N
17
DRCO1
DRCO1 N
18
DRCI2
DRCI2 N
19
DRCO2
DRCO2 N
20
0V
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 connector X22, see 3.1).
DRCI2/DRCO2 are connected to external placed drive units (backplane connector
X14, see 3.1).
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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).
X9
Pin
A
20
C
0V
21
MRCI1
MRCI1 N
22
MRCO1
MRCO1 N
23
MRCI2
MRCI2 N
24
MRCO2
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,
see 3.1).
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
A
Explanation
9
RD N
Read Data, pulses. Data pulses when reading the diskette
10
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.
12
WD N
Write Data, pulses. Data pulses when writing to the
diskette.
13
SSO N
Side Select, static active low. Indicates which side of
the diskette is active.
14
DIRC N
Direction in, static active low. Indicates that the
heads are to move inwards.
15
0V
X9
Pin
C
Explanation
9
IP N
Index, pulses. One pulse per cycle, c. every 200 milliseconds.
10
TR00 N
11
MO N
Motor on, static low. Starts the motor in the selected
unit.
12
WG N
Write Gate, pulses. Enables writing.
13
STEP N
14
HD N
15
0V
Product Manual
Track 00, active low. Indicates that the heads are
located at track 0 of the diskette.
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
(Figure 3).
X9
38
Pin
A
C
6
DATA4=TP
DATA4-N=TP-N
Product Manual
Troubleshooting Tools
3.4.7 CAN
X9
Pin
A
C
25
CANRLY2 N
CANRLY3 N
26
CAN_H
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
A
C
27
ENABLE9
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).
Product Manual
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Troubleshooting Tools
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Fault tracing guide
CONTENTS
Page
1 Fault tracing guide .......................................................................................................... 3
1.1 Starting Troubleshooting Work........................................................................... 3
1.1.1 Intermittent errors ........................................................................................ 3
1.1.2 Tools............................................................................................................. 3
1.2 Robot system ......................................................................................................... 4
1.3 Main computer DSQC 361 and memory board DSQC 323/324 ...................... 4
1.4 Robot computer DSQC 363 ................................................................................. 5
1.5 Panel unit DSQC 331............................................................................................ 5
1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant 6
1.6 Distributed I/O...................................................................................................... 8
1.7 Serial Communication.......................................................................................... 9
1.8 Drive System and Motors..................................................................................... 9
1.9 Teach Pendant....................................................................................................... 10
1.10 Measurement System ......................................................................................... 10
1.11 Disk Drive ............................................................................................................ 11
1.12 Fuses..................................................................................................................... 11
Product Manual
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Fault tracing guide
2
Product Manual
Fault tracing guide
1 Fault tracing guide
Sometimes errors occur which neither refer to an error message nor can be remedied
with the help of an error message.
To make a correct error diagnosis of these particular cases, you must be very experienced and have an in-depth knowledge of the control system. This section of the Product Manual is intended to provide support and guidance in any diagnostic work.
1.1 Starting Troubleshooting Work
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
Colour
Meaning
EN
Green
Indicates “go ahead” from the control system
MS
NS
ES 1 and 2
GS 1 and 2
AS 1 and 2
Green/red
Green/red
Yellow
Yellow
Yellow
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
6
Name
Meaning when “1” is displayed
BRAKE
Energise brake contactor (i.e. release brakes) and turn on
duty time counter
MONLMP
Turn on LED in motor-on push button
RUN CH1
Energise motor contactor chain 1
RUN CH2
Energise motor contactor chain 2
SOFT ASO
Choose delayed turn off of auto stop
SOFT ESO
Choose delayed turn off of emergency stop
SOFT GSO
Choose delayed turn off of general stop
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Fault tracing guide
Inputs DI
Name
Meaning when “1” is displayed
AS1
Auto stop chain 1 closed
AS2
Auto stop chain 2 closed
AUTO1
Mode selector chain 1; Auto operation
AUTO2
Mode selector chain 2; Auto operation
CH1
All switches in chain 1 closed
CH2
All switches in chain 2 closed
EN1
Enabling device chain 1 closed
EN2
Enabling device chain 2 closed
ES1
Emergency stop chain 1 closed
ES2
Emergency stop chain 2 closed
ENABLE
Enable from backplane
EXTCONT
External contactors closed
FAN OK
Fan in power supply running
GS1
General stop chain 1 closed
GS2
General stop chain 2 closed
K1
Motor contactor, chain 1, closed
K2
Motor contactor, chain 2, closed
LIM1
Limit switch chain 1 closed
LIM2
Limit switch chain 2 closed
MAN2
Mode selector chain 2; Manual operation
MANFS2
Mode selector chain 2; Manual full speed operation
MANORFS1
Mode selector chain 1; Manual or manual full speed operation
MON PB
Motor-On push button pressed
PTC
Over temperature in motors of manipulator
PTC Ext.
Over temperature in external device
SOFT ASI
Delayed turn off of auto stop (read back of digital output)
SOFT ESI
Delayed turn off of emergency stop (read back of digital output)
SOFT GSI
Delayed turn off of general stop (read back of digital output)
TRFOTMP
Over temperature in main transformer
24V panel
24V panel is higher than 22V
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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:
To indicate
Action
Off
No power
Check 24 V CAN
Green
Normal condition
Flashing green
Software configuration missing, standby state
Configure device
Flashing red/green
Device self testing
Wait for test to be
completed
Flashing red
Minor fault (recoverable)
Restart device
Red
Unrecoverable fault
Replace device
NS LED is:
To indicate
Action
Off
Not powered/not on-line
Flashing green
On-line, not connected
Green
On-line, connections established
Red
Critical link failure, incapable of communicating (duplicate MAC ID, or bus-off)
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.
Computer
Rotor position
DC link
Serial measurement
board
Torque reference
Drive Unit
M
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
pendant side 6, 24 panel.
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
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Fault tracing guide
12
Product Manual
ABB Flexible Automation AB
This 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 General Description ........................................................................................................ 3
1.1 Document Guidance ............................................................................................... 5
1.2 Caution.................................................................................................................... 6
1.3 Mounting Instructions for Bearings and Seals ....................................................... 6
1.3.1 Bearings ....................................................................................................... 6
1.3.2 Seals ............................................................................................................. 7
1.4 Instructions for Tightening Screw Joints................................................................ 9
1.5 Tightening Torques ................................................................................................. 10
1.5.1 Screws with slotted or cross recessed head.................................................. 10
1.5.2 Screws with hexagon socket head................................................................ 10
2 Axis 1 ............................................................................................................................... 11
2.1 Replacement of motor ............................................................................................ 11
2.2 Cabling axis 1 ......................................................................................................... 12
2.3 Replacing the gearbox ............................................................................................ 14
2.4 Dismounting joint bearing ...................................................................................... 15
2.5 Dismounting cooling axis 1.................................................................................... 16
3 Axis 2 ................................................................................................................................ 17
3.1 Replacing motor ..................................................................................................... 17
3.2 Replacing the gearbox ............................................................................................ 18
3.3 Replacing lower arm............................................................................................... 19
3.4 Replacing bearing in lower arm.............................................................................. 20
3.5 Dismounting balancing unit.................................................................................... 21
3.6 Replacing guiding ring, balancing unit................................................................... 23
3.7 Replacing bearings, balancing unit......................................................................... 24
3.8 Dismounting cables, lower arm/upper arm............................................................. 25
4 Axis 3 ................................................................................................................................ 27
4.1 Replacing motor ..................................................................................................... 27
4.2 Replacing gearbox .................................................................................................. 28
4.3 Dismounting parallel arm ....................................................................................... 29
4.4 Replacing parallel bar with bearings ...................................................................... 29
4.5 Dismounting upper arm, complete ......................................................................... 30
5 Link system ...................................................................................................................... 33
5.1 Replacing upper and lower rod............................................................................... 33
5.2 Replacing the link................................................................................................... 35
Product Manual IRB 640
1
Repairs
CONTENTS
Page
6 Pushbutton unit for releasing brakes ............................................................................ 37
6.1 Replacing pushbutton unit...................................................................................... 37
7 Axis 6 ................................................................................................................................ 39
7.1 Dismounting the tilt housing .................................................................................. 39
7.2 Replacing motor/gear axis 6................................................................................... 40
7.3 Checking play in axis 6 .......................................................................................... 41
8 Motor units ...................................................................................................................... 43
8.1 General ................................................................................................................... 43
8.2 Checking brake performance.................................................................................. 44
9 Calibration....................................................................................................................... 45
9.1 General ................................................................................................................... 45
9.2 Calibration procedure ............................................................................................. 45
9.3 Aligning the tilt housing ................................................................................. 51
9.4 Setting the calibration marks on the manipulator................................................... 52
9.5 Checking the calibration position........................................................................... 55
9.6 Alternative calibration positions ............................................................................ 55
9.7 Calibration equipment ............................................................................................ 57
10 Special Tools List........................................................................................................... 59
2
Product Manual IRB 640
Repairs
General Description
1 General Description
The industrial robot system IRB 640 comprises two separate units; the control cabinet
and the mechanical unit. The service of the mechanical unit is described in this document.
As regards service, the mechanical unit is divided into the following main parts:
• Electrical System
• Motor Units
• Mechanical System
The Electrical System is routed through the entire robot and consists of two major systems; power cabling and signal cabling. The power cabling feeds the robot axes' motor
units. The signal cabling feeds the various controlling parameters like axis positions,
motor revs, etc.
The AC type Motor Units provide the motive power for the various robot axes via
gears. Mechanical brakes, electrically released, lock the motor units when the robot is
inoperative for more than 180 seconds.
The Mechanical System has 4 axes, enabling the flexible robot motions.
Axis 3
Axis 2
Axis 6
Axis 1
Figur 1 The robot axes and motion patterns.
Product Manual IRB 640
3
General Description
Repairs
Axis No. 1 rotates the robot via a frame.
Axis No. 2, which provides the lower arm´s reciprocating movement, is supported in
the frame. The Lower Arm forms together with the Parallel Arm and the Parallel
Bracket, a parallelogram against the Upper Arm. The Parallel Bracket is mounted in
bearings in the Parallel Arm and in the Upper Arm.
Axis No. 3 provides elevation of the robot's upper arm.
Axis No. 6 is a turning motion. A connection is arranged for various customer tools at
the front end of the wrist in the Turn Disc. The tool (or manipulator) can be equipped
with pneumatic control via an external air supply. The signals to/from the tool can be
supplied via internal customer connections.
The Control Cabinet must be switched off during all service work on the robot!
Before doing any work on the robot measurement system (measurement board,
cabling), the accumulator power supply must always be disconnected.
When service work is finished, the calibration position should always be checked with
the system disc.
The Brake Release Unit should be connected as indicated in Section 7, Installation and
Commissioning, to enable movements of the axes.
Special care must be taken when the brakes are operated manually. This applies
particularly when the robot is started up, either for the first time or after a stoppage. The safety instructions in the Programming Manual must be complied with
at all times.
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Product Manual IRB 640
Repairs
General Description
1.1 Document Guidance
The subsequent chapters describe the type of service work that can be carried out by
the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective
module or component should be replaced on site. The faulty item should be sent to
ABB Flexible Automation for service.
Calibration. Recalibration of the robot may have to be carried out after replacing
mechanical unit parts or when the motor and feedback unit have been separated; or
when a resolver error has occurred or the power supply between a measurement board
and resolver has been interrupted. The procedure is described in detail in Chapter 9,
Calibration.
IMPORTANT! When work is done on the robot signal cabling, this may result in
the robot moving to incorrect positions.
After doing such work, it is important that the robot calibration position is
checked as described in Chapter 9.5, Checking the calibration position. If a calibration fault is discovered, the robot must be recalibrated as described in Chapter
9, Calibration.
Tools. Two types of tools are required for various service jobs involving dismantling;
on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other
hand, special tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However,
service work requiring the use of special tools is described in this manual.
Foldouts. In the Spare Parts chapter of this manual, there are a number of foldouts
illustrating the robot parts, intended to facilitate quick identification of both the type of
service required and the composition of the various components. The parts are item
numbered on the foldouts. The foldouts are referred to in the Manual text within
“arrow heads” (< >) as exploded view numbers. Where reference is made to foldouts,
other than those specified in the paragraph title, the foldout number is included in the
item number reference, for example <5/19> or <10:2/5>, the digit(s) before the stroke
referring to the foldout number.
Numbers in brackets ( ) refer to figures in the text.
The foldouts also include information such as article number, designation and relevant
data.
N.B. This manual is not to be considered as a substitute for a proper training
course. This document is intended for use after the course has been completed.
Product Manual IRB 640
5
General Description
Repairs
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 to have a suitable lifting device available.
The robot should always be switched to MOTORS OFF before allowing anyone to
enter its working space.
1.3 Mounting Instructions for Bearings and Seals
1.3.1 Bearings
1.
Let a new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.
2.
Ensure that all parts included in the bearing fitting are free from burrs, grinding
waste and other contamination. Cast components must be free from foundry sand.
3.
Bearing rings, inner rings and roller elements must under no circumstances be
subjected to direct impact. Also, the roller elements must not be exposed to any
stresses during the assembly work.
Tapered Bearings
4.
The bearing should be tensioned gradually until the recommended pre-tension is
achieved.
5.
It is important to note that the roller elements must be rotated a specified number of
turns before pre-tensioning is carried out, and also rotated during the pre-tensioning
sequence.
6.
The above procedure must be carried out to enable the roller elements to adjust to
the correct position against the race flange. Also, it is important that the bearing
is properly aligned, as this will directly affect the lifespan of the bearing.
Greasing Bearings
6
7.
The bearing must be greased after fitting. The main reason for this is the requirement
for cleanliness.
8.
Grooved ball bearings should be filled with grease from both sides.
9.
Tapered roller bearings and axial needle bearings shall be greased in the split condition.
Product Manual IRB 640
Repairs
General Description
10.
The bearings must not be completely filled with grease. However, if space is
available beside the bearing fitting, the bearing may be totally filled with grease
when mounted, as surplus grease will be thrown out from the bearing when the
robot is started up.
11.
During operation, the bearing should be filled to 70-80% of the available volume.
12.
Ensure that grease is handled and stored properly, to avoid contamination.
1.3.2 Seals
1.
The commonest cause of leakage is incorrect fitting.
Rotating Seals
2.
The sealing surfaces should be protected during transport and mounting.
3.
The seal should be kept in the original wrappings or be well protected.
4.
Sealing surfaces must be inspected before mounting. If scratches or damage are
found, that may result in future leakage, the seal must be replaced.
5.
Seals should also be checked before mounting to ensure that:
• there is no damage to the sealing edge (feel with a fingernail)
• the seal is of the correct type (provided with cutting edge)
• there is no other damage.
6.
Grease the seal just before fitting it, but not too early as there is a risk of dirt and
foreign particles adhering to the seal. The space between the dust tongue and
sealing lip should be filled to 2/3 with grease. The rubber coated external diameter must also be greased.
7.
The fitting of seals and gears must be carried out on clean workbenches.
8.
Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the
pumping effect.
9.
Always mount the seal with a mounting tool. Never hammer directly on the seal,
as this may result in leakage.
10.
Use a protective sleeve for the sealing lip during mounting, when sliding over
threads, keyways, etc.
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General Description
Repairs
Flange Seals and Static Seals
11.
Check the flange surfaces. They must be even and free from pores. It is easy to
check flatness using a gauge on the fastened joint (without sealing compound).
12.
Differences in surface level or the presence of burrs due to incorrect machining
are not permissible. If flange surfaces are defective, the parts must not to be used,
because leakage could result.
13.
The surfaces must be properly cleaned in accordance with ABB ROBOTICS
PRODUCTS recommendations.
14.
Distribute the sealing compound evenly over the surface, preferably with a brush.
15.
Tighten the screws evenly when fastening the flange joint.
O-rings
8
16.
Check the O-ring grooves. The grooves must be geometrically correct and free
from pores and contamination.
17.
Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.
18.
Ensure that the correct O-ring size is used.
19.
Tighten the screws evenly when assembling.
20.
Defective O-rings and O-ring grooves must not be used.
21.
Fitting defective parts will result in leakage. Grease the O-ring with lubricant
before mounting.
Product Manual IRB 640
Repairs
General Description
1.4 Instructions for Tightening Screw Joints
General
It is of the utmost importance that all screw joints be tightened with the correct torque.
Application
The following tightening torques are to be used for all screw joints in metallic materials
unless otherwise specified in the text.
These instructions do not apply to screw joints comprising soft or brittle materials.
For screws with a higher property class than 8.8, the data for 8.8 must be used unless
otherwise specified.
Screws treated with Gleitmo (lubricated)
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 that are not Gleitmo treated, these should first be lubricated with Molycote 1000 and tightened to the specified torque.
Assembly
Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used
when specified in the text.
Screws lubricated with Molycote 1000 and then torque tightened, should also to be
lubricated between the washer and the head of the screw.
Screws with dimension M8 or larger should be tightened with a torque-wrench, if possible.
Screws with dimension M6 or smaller may be tightened to the correct torque using
tools without torque indication, by personnel with adequate mechanical training and
instruction.
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General Description
Repairs
1.5 Tightening Torques
1.5.1 Screws with slotted or cross recessed head
Tightening torque - Nm
Dimension
class 4.8
“Dry”
M 2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
1.5.2 Screws with hexagon socket head
Tightening torque - Nm
10
Dimension
class 8.8
“Dry”
class 10.9
Molycote 1000
Gleitmo 610
class 12.9
Molycote 1000
Gleitmo 610
M5
6
M6
10
M8
24
28
35
M 10
47
55
70
M 12
82
95
120
M 16
200
235
300
Product Manual IRB 640
Repairs
Axis 1
2 Axis 1
2.1 Replacement of motor
Refer to foldout no. 2.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Remove the cover in the frame between axes 2 and 3.
2.
Unscrew the 3 screws on the top of motor 1. Remove the cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R2.MP1 and R3.FB1 in the motor.
5.
Unscrew the motor flange, 4 screws <9>. Use two screws in the threaded holes
(M8) on the motor flange, to push out the motor from its attachment.
6.
Loosen screw <15>, fit a 150 mm screw, and pull off the pinion with the help of a
puller.
Mounting:
7.
Mount a threaded pin in the motor shaft and press the gear on to the shaft with a
nut and washer. Mount screw <15> through the gear, torque 70 Nm, Loctite 243.
Axial force through the bearings in the motor is prohibited.
8.
Ensure that assembly surfaces are clean and unscratched.
9.
Apply sealing liquid Permatex 3 under the motor flange.
10. Mount the motor, grease screw <9> with Molycote 1000 and tighten with a torque
of 50 Nm.
11. Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screws for motor, item 9:
50 Nm.
Screw for motor gear, item 15:
70 Nm.
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11
Axis 1
Repairs
2.2 Cabling axis 1
Dismounting:
Refer to foldouts 2, 2:1 and 3.
1.
Place axis 1 in calibration position 0. Shut down the robot system with the mains
switch.
2.
Loosen the control cable connectors in the robot base.
3.
Loosen the covers <2/21, 22> on base cabling from the base by unscrewing screws
<2/18>.
4.
Loosen the support rail <3/3>, screws <3/6> and remove it forwards to a position
as far away from the base cabling as possible.
Do not remove the screws!
5.
Loosen the base cabling at the bottom of the base <3/1>.
Do not remove the screws!
6.
Tighten all screws <3/6> again after the cabling has been removed.
To avoid that the base plate <3/2> rotates and to make dismounting and mounting
of the cabling easier.
7.
Take out the cover <2/22> and disconnect the earth wire from the contact plate in
the base.
8.
Loosen the base cabling at the frame, screws <2:1/25>. The screws must be
removed.
9.
Loosen the cover over axis 1 motor, the brake release unit and the serial measurement board.
Caution!
The serial measurement board is an electrostatic sensitive device.
Use a wrist strap.
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Product Manual IRB 640
Repairs
Axis 1
10. Disconnect the contacts to the base cabling in the frame:
R2.SMB(X2)
R2.CP
R2.CS
R2.CB
R2.MP1
(inside motor 1)
R2.MP2
R2.MP3
R2.MP6
R2.FAN
(connected only for PT or optional)
R2.CPV
R3.BU1-6(X8)
R3.BU1-3(X9)
R3.BU4-6 (X10)
R3.SW2-3
R2.SMB 1-2
Air hose
(on serial measurement board)
(must be loosened at the nipple on the base and the nipple in
the frame)
11. Feed the cabling carefully through the hole in the left side of the base.
Mounting:
12. Feed the cable inside the base through the hole on the left side. The robot should
be positioned in calibration position 0. Pull the cables through the hole in the frame
and pull out connectors to their correct positions.
13. Mount the screws <2:1/25> with washers <2:1/26> which hold the cabling to the
frame. Add Loctite 243 and tighten.
14. Connect all contacts inside the frame and at the brake release unit and serial measurement board. Mount the brake release unit and serial measurement board, use
Loctite 243.
15. Connect the earth wire.
16. Unscrew screws <3/6> approx. 8 mm. See foldout 3.
17. Place the cover <2/22> in position.
18. Place the cabling in position on the bottom of the base.
19. Remove screws <3/6> which keep the cabling fixed to the bottom of the base, one
at the time and add Loctite 243 and tighten it.
20. Mount support rail <3/3>. Add Loctite 243 and tighten.
21. Assembly all covers, use Loctite 243.
Note! All removed straps must be refitted.
Product Manual IRB 640
13
Axis 1
Repairs
2.3 Replacing the gearbox
Refer to foldouts no. 2 and 4.
Dismounting:
1.
Dismount motor and the cabling, as described in Chapter 2.1, Replacement of
motor and Chapter 2.2, Cabling axis 1.
2.
Disconnect the cables and the air hose that comes through the lower arm, and is
connected to the frame.
3.
Attach a hoist in existing lifting eye bolts.
For instructions about lifting, see Chapter 7, Installation and Commissioning.
To facilitate dismounting, it is essential that the arm system is evenly balanced.
Move the lower arm slightly backwards and allow the upper arm to move down
as far as possible, in order to concentrate the centre of gravity as close as possible.
If there is any load on the wrist, or any other equipment, the positioning may be
affected.
4.
Unscrew screws <2/43, 45> for the gear. Accessible through holes in the frame.
5.
Remove screws <2/6> holding the joint bearing.
6.
Lift the arm system straight up.
7.
Place the arm system on some kind of support.
Make sure that the arm system is properly supported, so that the gearbox can be
safely removed.
8.
Loosen screws <4/6> for the gearbox.
Mounting:
9.
Mount two guide pins, M12x200 under the frame, to facilitate mounting of the
friction ring and gear.
10. Fit O-ring <4/11>, friction ring <4/13> and gear <4/12>. Apply Molycote 1000 on
the screws <4/6> and tighten to a torque of 120 Nm.
11. Mount two guide pins, M12x300 in the manipulator base.
12. Mount O-ring <2/12> at the bottom in the base.
13. Lift the arm system and then lower it carefully until the joint bearing is just about
to enter the bearing seat.
14. Align the holes in the bearing <4/2> with the holes in the base, with two screws.
14
Product Manual IRB 640
Repairs
Axis 1
15. Lower the arm system.
16. Apply Loctite 577 on screws <2/43, 45>. Do not tighten the screws. Rotate the
gear approx. 10 turns (input shaft) forwards and backwards, using the tool
3HAC 0266-1. Tighten first screws <2/43> to a torque of 300 Nm and then screws
<2/45> to a torque of 120 Nm.
Note! The sequence when tightening the screws.
17. Mount screws <2/6>, lubricate with Molycote 1000 and tighten to a torque of
120 Nm.
18. Mount motor and cabling as described in Chapter 2.1, Replacement of motor and
Chapter 2.2, Cabling axis 1.
19. Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint gear/base, item 2/43:
Screw joint gear/base, item 2/45:
Screw joint gear/frame, item 4/6:
Screw joint bearing/base, item 2/6:
300 Nm
120 Nm
120 Nm
120 Nm
2.4 Dismounting joint bearing
Refer to foldout 4.
Dismounting:
1.
Dismount the arm system as described in Chapter 2.3, Replacing the gearbox.
2.
Unscrew screws <3> and remove the joint bearing.
Mounting:
3.
Apply grease to the bearing seat and push it on with screws <3>. Lubricate screws
with Molycote 1000 and tighten with a torque of 120 Nm.
4.
Refit the arm system as described in Chapter 2.3, Replacing the gearbox.
Tightening torque:
Screw joint bearing, item 3: 120 Nm.
Product Manual IRB 640
15
Axis 1
Repairs
2.5 Dismounting cooling axis 1
Refer to foldout 10.
Dismounting:
1.
Dismount cover in the frame between axes 2 and 3.
2.
Disconnect fan cabling <12>, R3.FAN.
3.
Loosen nuts <7>.
4.
Remove the fan <1>.
Mounting:
5.
16
Mount in reverse order.
Product Manual IRB 640
Repairs
Axis 2
3 Axis 2
3.1 Replacing motor
Refer to foldout 5.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Move the lower arm to the position where it is possible to secure the arm with
screws, through the holes in the lower fixing points of the balancing springs.
Tighten the screws into the lower arm.
2.
Unscrew the 3 screws on top of motor 2. Remove the cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R3.MP2 and R3.FB2 in the motor.
5.
Attach a hoist to the motor. The weight of the motor is 17 kg.
6.
Loosen the screws <1.31> for the motor.
7.
Pull out the motor. (In case of difficulty, use the threaded M8 holes on the motor
flange to push the motor out.)
8.
Unscrew screw <1.30> and mount a screw with a length of 150 mm and pull off
the gear with a puller.
Mounting:
9.
Fit a fully threaded pin in the motor shaft and press the gear on to the shaft with a
nut and a washer. Mount screw <1.30> through the gear, torque 70 Nm, Loctite
243.
This is to avoid axial force through the bearings in the motor.
10. Ensure that assembly surfaces are clean and unscratched.
11. Mount O-ring <1.28> using some grease.
12. Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten with a
torque of 50 Nm.
Do not forget to remove the locking screws in the lower arm!
13. Calibrate the robot as described in Chapter 9, Calibration.
Product Manual IRB 640
17
Axis 2
Repairs
Tightening torque:
Screws for motor, item 1.31:
50 Nm
Screw for gear, item 1.30:
70 Nm
3.2 Replacing the gearbox
Refer to foldout 5.
Dismounting:
1.
Remove motor as in Chapter 3.1, Replacing motor.
2.
Unscrew screws <1.38.2> and remove the motor socket <1.38.1>.
3.
Mount 2 guide pins, M12, through the gearbox.
4.
Loosen the screws <1.5> and <1.7>.
5.
Pull the gearbox <1.3> out, suspended on the guide pins.
Mounting:
6.
Clean the surfaces in the frame, lower arm and gearbox.
7.
Mount 2 guide pins, M12.
8.
Mount friction rings <1.16, 1:37> and O-ring <1.4>.
9.
Put the gearbox <1.3> on the 2 guide pins and place the friction ring <1.16> on to
the gearbox.
10. Mount screws <1.5> and <1.7>, lubricate with Molycote 1000 and tighten screw
<1.7> with 300 Nm and screw <1.5> with 120 Nm.
11. Mount O-ring <1.14>.
12. Suspend the motor socket on the 2 guide pins.
Note the position of the magnetic plugs.
13. Mount screws <1.38.2>, lubricate with Molycote 1000 and tighten with a torque of
120 Nm.
14. Mount motor as described in Chapter 3.1, Replacing motor.
Tightening torque:
18
Screw joint gear box/lower arm, item 1.7:
300 Nm
Screw joint gear box/lower arm, item 1.5:
120 Nm
Screw joint motor socket/frame, item 1.38.2:
120 Nm
Product Manual IRB 640
Repairs
Axis 2
3.3 Replacing lower arm
Refer to foldout nos. 1 and 1:1.
Dismounting:
1.
Run the lower arm to the position where it is possible to secure the arm with
screws, through the holes for the lower fixing points of the balancing spring.
2.
Dismount the balancing weight for axis 3.
3.
Attach a hoist to the upper arm.
4.
Remove the clamps, screws <1/3.160>, <1/3.142> and lift the parallel bar away.
5.
Dismount the linkage according to Chapter 5, Link system.
6.
Remove the cables in the lower arm as described in Chapter 3.8, Dismounting
cables, lower arm/upper arm.
Do not remove the cables from the upper arm.
7.
Dismount the upper arm as described in Chapter 4.5, Dismounting upper arm,
complete.
8.
Dismount the balancing unit <1:1/1> as described in Chapter 3.5, Dismounting
balancing unit or Chapter 3.6, Replacing guiding ring, balancing unit.
8.
Attach a hoist to the under arm.
9.
Dismount motor and gearbox for axis 2 as described in Chapter 3.2, Replacing the
gearbox.
10. Dismount motor and gearbox for axis 3 as described in Chapter 4.2, Replacing
gearbox.
11. Remove the 2 locking screws for the lower arm and gently lift the lower arm
together with the parallel arm, straight up.
12. Dismount the parallel arm as described in Chapter 4.3, Dismounting parallel arm.
Mounting:
13. Mount the parallel arm as described in Chapter 4.3, Dismounting parallel arm.
14. Lift the lower arm with mounted parallel arm in position.
15. First mount the motor and gearbox for axis 2, as in Chapter 3.2, Replacing the
gearbox.
Product Manual IRB 640
19
Axis 2
Repairs
16. Then mount the motor and gearbox for axis 3 as in Chapter 4.2, Replacing gearbox.
17. Secure the lower arm with the locking screws.
18. Mount the upper arm as in Chapter 4.5, Dismounting upper arm, complete.
19. Mount the parallel bar as in Chapter 4.4, Replacing parallel bar with bearings.
20. Mount the linkage according to Chapter 5, Link system.
21. Mount the cables as in Chapter 3.8, Dismounting cables, lower arm/upper arm.
22. Mount the balancing weight for axis 3, lubricate screws <1/3.142> with Molycote
1000 and tighten with 300 Nm.
23. Mount the balancing unit for axis 2 as described in Chapter 3.5, Dismounting balancing unit or Chapter 3.6, Replacing guiding ring, balancing unit.
Do not forget to remove the locking screws!
24. Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint balancing weight/parallel arm, item 1/3.142: 300 Nm.
3.4 Replacing bearing in lower arm
Refer to foldout no. 6:1.
Dismounting:
1.
Remove the lower arm as in Chapter 3.3, Replacing lower arm.
2.
Place the lower arm on a workbench or similar.
3.
Dismount the parallel arm as in Chapter 4.3, Dismounting parallel arm.
4.
Remove the bearings <3> with a puller.
Mounting:
20
5.
Mount the spacer <4>.
6.
Heat up the bearing <3> to max. 120oC before mounting it on the parallel arm <2>.
7.
Mount parallel arm as in Chapter 4.3, Dismounting parallel arm.
8.
Mount lower arm as in Chapter 3.3, Replacing lower arm.
Product Manual IRB 640
Repairs
Axis 2
3.5 Dismounting balancing unit
Refer to foldout no. 1:1.
Dismounting:
1.
Move the lower arm to the sync. position. Secure it by means of an M16x140
screw through the lower pivot shaft on the opposite side of the balancing unit.
2.
Insert an M10 screw at the top of the cylinder to neutralize the spring force. The
length of the cylinder is now locked.
3.
Attach a hoist to the balancing unit.
Make sure that the shaft between the upper and lower arms does not rotate when
unscrewing the KM nut. The KM nut is locked with Loctite 243.
4.
Remove the KM nuts <5> with KM socket, size 4-KM 8.
Mounting:
5.
Place rings <3>, support washers <4>, sealing rings <2> and the inner races of the
bearings on the upper and lower pivot shaft.
6.
Install the auxiliary shafts on the upper and lower shafts. (Upper shaft: auxiliary
shaft 3HAB 6558-1, lower shaft: auxiliary shaft 3HAB 6567-1), see Figure 2.
7.
Hang up the new balancing unit on the upper auxiliary shaft.
Adjust the length between the bearings by means of the M10 screw. This length
should preferable be 0.5 mm too short than 0.1 mm too long. If the distance is too
long the bearings may be damaged when erecting the balancing unit.
Carefully install the balancing unit on to the upper and lower shaft.
8.
Fit the lubricating tool 3HAC 4701-1. The tool should be tightened to the bottom
position only by hand power.
9.
Grease through the nipple. Continue greasing until the grease excudes behind the
inner sealing ring. Repeat procedure for the other bearings.
10. Remove the lubricating tool and clean the threads on the shaft ends free from
grease.
11. Remount the outer sealing rings, apply some grease on the support washers, apply
Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 5060 Nm.
12 Check play (min. 0,1) between support washers <2, 5> and bearing seat <7> at
both bearings.
13. Remove the M10x50 screw at the top of the cylinder. Remove the M16x140 screw
on the lower arm.
Product Manual IRB 640
21
Axis 2
Repairs
12
4
Inner race
5
6
Aux. shaft
3HAB 6558-1
3
12
34
56
Loctite 243
50 Nm
min 0.1
min 0.1
7
Figure 2 Mounting the balancing unit.
22
Product Manual IRB 640
Repairs
Axis 2
3.6 Replacing guiding ring, balancing unit
1
Move axis 2 to a position where the balancing unit is in the horizontal position.
2
Remove the circlip from the end cover of balancing unit. See Figure 3.
3
Remove the worn out guiding ring and clean the piston rod. See Figure 3.
4.
With the smallest outer diameter facing outwards, force the new guiding ring over
the piston rod. Locate the ring in the end cover. Use tool 3HAC 0879-1.
See Figure 3
5.
Install the circlip.
6.
Lubricate the piston rod, see Maintenance, Chapter 2.6, Lubricating piston rod,
balancing unit axis 2.
Tool 3HAC 0879-1
Guide ring
Circlip
Smallest o.d.
Circlip
Figure 3 Guiding ring, balancing unit.
Product Manual IRB 640
23
Axis 2
Repairs
3.7 Replacing bearings, balancing unit
Use recondition kit 3HAC 2840-1.
1.
Dismantle the balancing unit according to Chapter 3.5, Dismounting balancing
unit.
2.
Push out the old bearing, using tool 3HAC 1981-1. See Figure 4.
Press
Tool 3HAC 1981-1
Support
Old bearing
Figure 4 Dismounting of bearing.
3.
Turn the tool upside down. Place the new bearing on the tool with the bearing
number upwards (facing the tool). Push the new bearing down according to
Figure 5.
Press
New bearing
Support
Figure 5 Mounting of bearing.
24
4.
Replace the guiding ring and the circlip according to Chapter 3.6, Replacing guiding ring, balancing unit.
5.
Mount the balancing unit according to Chapter 3.5, Dismounting balancing unit.
Product Manual IRB 640
Repairs
Axis 2
3.8 Dismounting cables, lower arm/upper arm
Refer to foldout nos. 1:2, 2 and 7.
Dismounting:
1.
Disconnect connectors R2.MP6, R2.CP, R2.CS inside cover between axis 2 and 3
in the frame.
2.
Disconnect connector (X5) on the serial measurement board <1:2/119>, located in
the frame.
3.
Remove the small covers in the cover <1:2/112> and feed the cables gently out
from the frame. Take the cables through the hole in the plate. Loosen the air hose.
4.
Unscrew the holders for the cabling, see foldouts for location.
Make a written note of the relative positions and order of the cables and air hose,
to facilitate refitting in the correct way.
Mounting:
6.
Mount in reverse order.
Adjust the length of the cable between the cable holders at the top of the lower
arm and the holder on the upper arm, at the longest distance when the upper arm
is moved down. The cable that comes out from the upper arm forms a loop down
against the parallel bar. The loop should be big enough so that it runs quite close
to the inside of the cover.
Product Manual IRB 640
25
Axis 2
26
Repairs
Product Manual IRB 640
Repairs
Axis 3
4 Axis 3
4.1 Replacing motor
Refer to foldout 5.
Dismounting:
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.
1.
Lower the balancing weight to its lowest position and secure axis 3 with a
hoist, or mount two extra mechanical stops on each side of the moving stop
on axis 3, to lock the movement of axis 3.
Danger! Be careful! Make sure that the balancing weight or the upper arm are
locked in their positions and that they cannot move when the motor with brake is
dismounted.
2.
Unscrew the 3 screws on the top of motor 3. Remove the cover.
3.
Unscrew the 4 cable inlet cover screws.
4.
Disconnect connectors R3.MP3 and R3.FB3.
5.
Attach a hoist to the motor. The weight of the motor is 17 kg.
6.
Unscrew the screws <1.31> for the motor.
7.
Pull out the motor.
8.
Loosen screw <1.30> and mount a screw with a length of 150 mm and pull off
the gear with a puller.
Mounting:
9.
Mount a fully threaded pin in the motor shaft and press the gear on to the shaft
with a nut and washer. Mount screw <1.30> through the gear, torque 70 Nm,
Loctite 243.
This is to avoid axial force through the bearings in the motor.
10.
Ensure that the assembly surfaces are clean and unscratched.
11.
Mount O-ring <1.28>, applying some grease.
12.
Mount motor, lubricate screws <1.31> with Molycote 1000 and tighten to
torque 50 Nm.
Do not forget to remove the two extra mechanical stops, if they are used.
Product Manual IRB 640
27
Axis 3
Repairs
13.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screws for motor, item 1.31:
50 Nm
Screw for gear, item 1.30:
70 Nm
4.2 Replacing gearbox
Refer to foldout nos. 5.
Dismounting:
1.
Dismount motor as described in Chapter 4.1, Replacing motor.
2.
Unscrew screws <1.38.2> and dismount the motor socket <1.38.1>.
3.
Mount 2 guide pins, M12 through the gearbox.
4.
Loosen screws <1.5> and <1.7>.
5.
Pull out the gear box <1.3>, hanging on the guide pins.
Mounting:
6.
Clean the surfaces in the frame, lower arm and gearbox.
7.
Mount 2 guide pins, M12.
8.
Mount friction rings <1.16, 1.37> and O-ring <1.4>.
9.
Put the gear box on the 2 guide pins and place the friction ring <1.16> on to the
gearbox.
10.
Mount screws <1.5> and <1.7>, lubricate with Molycote 1000 and tighten
screw <1.7> with 300 Nm and screw <1.5> with 120 Nm.
11.
Mount O-ring <1.14>.
12.
Put the motor socket on the 2 guide pins.
Note! The position of the magnetic plugs.
28
13.
Mount screws <1.38.2>, lubricate with Molycote 1000 and tighten to a torque of
120 Nm.
14.
Mount the motor as described in Chapter 4.1, Replacing motor.
Product Manual IRB 640
Repairs
Axis 3
Tightening torque:
Screw joint gearbox/parallel arm, item 1. 7:
Screw joint gearbox/parallel arm, item 1.5:
Screw joint motor socket/frame, item 1.38.2:
300 Nm
120 Nm
120 Nm
4.3 Dismounting parallel arm
Refer to foldout no. 6 and 6:1.
Dismounting:
1.
Remove the lower arm as in Chapter 3.3, Replacing lower arm.
2.
Place the arm on a workbench.
3.
Attach a hoist to the parallel arm.
4.
Force the parallel arm to the right, seen from the rear.
5.
Lift the parallel arm away.
Mounting:
6.
Place the parallel arm in position.
7.
Press the parallel arm into the lower arm.
8.
Mount the lower arm as described in Chapter 3.3, Replacing lower arm.
4.4 Replacing parallel bar with bearings
Refer to foldout no. 1.
Dismounting:
IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the
balancing weight for axis 3 cannot fall down, and secure the upper arm with a
hoist or similar.
1.
Attach a hoist to the parallel bar.
NOTE! Mark the clamps so that they can be refitted in the same place.
2.
Dismount clamps, screws <3.142> by the parallel arm.
3.
Dismount clamps, screws <3.160> by the upper arm. Lift the bar away.
Product Manual IRB 640
29
Axis 3
Repairs
Mounting:
4.
Lift the parallel bar in position.
5.
Lubricate screws with Molycote 1000 and tighten to a torque of 300 Nm.
6.
Make sure that the clamps are tightened symmetrically.
Do not forget to remove the 2 extra mechanical stops!
Tightening torque:
Screws, clamps, item 3.142: 300 Nm.
4.5 Dismounting upper arm, complete
Refer to foldout nos. 1 and 1:1.
Dismounting:
IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the balancing weight for axis 3 cannot fall down.
1.
Dismount balancing unit as described in Chapter 3.5, Dismounting balancing
unit or Chapter 3.6, Replacing guiding ring, balancing unit.
2.
Remove the cables and air hose inside the lower arm as in Chapter 3.8, Dismounting cables, lower arm/upper arm
3.
Attach a hoist to the upper arm. See Figure 6.
Figure 6 Lifting the upper arm.
30
4.
Dismount the linkage as described in Chapter 5, Link system.
5.
Unscrew the clamps, screws <1/3.143> on the upper arm for the parallel bar. Let
the bar rest on the weights. NOTE! Mark the clamps.
5.
Remove the KM nut<1:1/136> on each shaft.
Product Manual IRB 640
Repairs
Axis 3
6.
Remove the stop screws <1:1/137> in the lower arm.
7.
Unscrew the shafts <1:1/203>. The bearing is pressed out with the shaft.
Note! Be careful with the threads on the shafts.
8.
Lift the upper arm away.
Mounting:
9.
Place the upper arm in position.
NOTE! Mount the left side first, complete, robot seen from behind!
10.
Mount sealing ring <1:1/140>, turn the largest diameter inwards.
11.
Mount the outer ring of the bearing in the upper arm.
12.
Mount the V-ring <1:1/134> on the shaft.
13.
Mount the shaft <1:1/203>. Lubricate the threads with Molycote 1000 and
tighten to a torque of 300 Nm.
14.
Apply Loctite 243 on stop screw <1:1/137> and tighten to torque 34 Nm.
15.
Insert the distance ring <1:1/138> on the shaft (only on the left side).
16.
Mount the bearing <1:1/133>.
17.
Insert the NILOS-ring <1:1/135> and distance ring <1:1/139>.
18.
Mount the KM nut. Apply Loctite 243 and tighten the nut, then loosen the nut
again and tighten to a torque of 90 Nm.
19.
Then mount the right side, paragraphs 12-18 (similar to the left side, except for
the distance ring <1:1/138). Just tighten the nut to 90 Nm.
20.
Mount the parallel bar. Use Molycote 1000 and tighten screws <1/3.143> for
the clamp with a torque of 300 Nm.
21.
Mount linkage as described in Chapter 5, Link system.
22.
Mount the cabling as described in Chapter 3.8, Dismounting cables, lower arm/
upper arm.
23.
Mount the balancing units as described in Chapter 3.5, Dismounting balancing
unit or Chapter 3.6, Replacing guiding ring, balancing unit.
NOTE! Remove the 2 extra mechanical stops!
Product Manual IRB 640
31
Axis 3
Repairs
Tightening torque:
32
Shafts, item 1:1/203:
300 Nm
KM nut, item 1:1/136:
90 Nm
Screws, clamps, item 1/3.142, 1/3.160:
300 Nm
Product Manual IRB 640
Repairs
Link system
5 Link system
5.1 Replacing upper and lower rod
Refer to foldouts 1:4 and 7
Dismounting:
Upper rod
1.
Lock the tilt house <7/4>, through the tilt house into the upper arm with a
screw.
2.
Unscrew KM-nuts <205.24> at both ends of the upper rod.
3.
Attach a hoist to the rod.
4.
Hold the tilt in balance.
5.
Remove the upper rod.
Lower rod
The bearings can take a skew setting. But be careful.
6.
Lock the tilt house <7/4>, through the tilt house into the upper arm with a
screw.
7.
Loosen the upper rod at the tilt house.
8.
Dismount cover <205.24> by deformation (a new cover must be fitted).
9.
Remove KM-nut <205.6>.
10.
Secure the link <205.40> so it cannot rotate when the lower rod is removed.
11.
Remove screw <205.29>.
12.
Dismount support washer <205.28> together with friction washer <205.32>.
13.
Attach a hoist to the lower rod and remove it.
Product Manual IRB 640
33
Link system
Repairs
Mounting:
Lower rod
The bearings can take a skew setting. But be careful.
14.
Apply Loctite on the shaft before mounting the ring <205.31>, see foldout 1:4
view D-D and E-E. Mount ring <205.31> on both the upper and lower shaft.
15.
Mount the lower rod <205.20> with bearings <205.21>.
16.
Refill the bearing with grease.
17.
Mount KM-nut <205.6> at the upper shaft. Tighten to 50 Nm.
18.
Mount friction washer <205.32>, support washer <205.28> and screw
<205.29> use Loctite 243.
19.
Mount a new cover <205.24>.
Upper rod
Note! When changing bearing, pushing a bearing is only allowed on its text
side. The other side is not hard enough.
20.
Place ring <205.4>, support ring <205.5>, sealing ring <205.3> and the inner
races of the bearings on the front and rear shaft. Grease the bearing.
21.
Mount the upper rod <205.1>.
22.
Mount sealing ring <205.3>, support washer <205.5> and KM-nuts <205.6>,
use Loctite 243. Tighten to a torque of 50 Nm.
23.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
KM-nut, item 205.6:
34
50 Nm
Product Manual IRB 640
Repairs
Link system
5.2 Replacing the link
Refer to foldout 1:4
Dismounting:
Secure the link with a hoist or similar before dismounting the rods. This is to prevent the link from swinging down and damaging the thread on the fixing point for
the upper rod against the lower arm.
1.
Remove the upper and lower rods as described on Chapter 5.1, Replacing upper
and lower rod.
2.
Remove cover <205.46> by deformation (a new cover must be fitted).
Make sure that the shaft between the upper and lower arms does not rotate
when unscrewing the KM nut. The KM nut is locked with Loctite 243.
3.
Unscrew KM-nut <205.6>.
4.
Attach a hoist to the link.
5.
Pull out the link.
Mounting:
6.
Apply Loctite on the shaft before mounting the ring <205.47>.
Mount support ring <205.47>.
7.
Mount the inner race of bearing <205.41>.
8.
Mount the link.
9.
Mount KM-nut <205.6>, use Loctite 243. Tighten to a torque of 90 Nm.
10.
Swing the link, by hand, backwards and forwards a couple of times and then
retighten KM-nut <205.6> again.
11.
Fit a new cover <205.46>.
12.
Refill the bearings with grease, remove plug <205.48> and insert a nipple.
13.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
KM-nut, item 205.6:
Product Manual IRB 640
90 Nm
35
Link system
36
Repairs
Product Manual IRB 640
Repairs
Pushbutton unit for releasing brakes
6 Pushbutton unit for releasing brakes
6.1 Replacing pushbutton unit
Refer to foldout no. 2
Dismounting:
1.
Remove the pushbutton unit <3> located in the frame.
2.
Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10).
Mounting:
3.
In reverse order.
Product Manual IRB 640
37
Pushbutton unit for releasing brakes
38
Repairs
Product Manual IRB 640
Repairs
Axis 6
7 Axis 6
7.1 Dismounting the tilt housing
Refer to foldout no. 7
Dismounting:
1.
Remove the drive unit axis 6 as described in Chapter 7.2, Replacing motor/gear axis 6
2.
Attach a hoist to the tilt housing.
3.
Dismount the upper rod in the front as described in Chapter 5.1, Replacing upper and
lower rod.
4.
Remove covers <15> and <16> on both sides by deformation or push the covers from
inside with thickest possible 16 mm tool. If the covers are not deformed they can be
reused.
5.
Unscrew KM-nuts <14>.
6.
Mount tool 3HAC 2486-1 and pull out the shaft <9> on both sides.
7.
Lift the tilt housing away.
Mounting:
9.
Mount the sealings <10> in the tilt housing. Use tool 3HAC 0905-1.
10.
Mount the bearings <11> in the tilt housing. Use tool 3HAC 3437-1.
11.
Apply a little grease in the hole for the shafts. Apply grease also to both the shafts.
12.
Insert shaft <9> on the same side as the balancing unit (left side of robot as seen from
behind).
13.
Position the distance piece 3HAC 2984-1 between the upper arm and the tilt housing on
the left side of the upper arm, seen from behind. Press the shaft <9> into position using
tool 3HAC 3409-1 (max. pressing force 6 tons).
14.
Remove the distance piece and fit the KM nuts <14>. Tighten to a torque of 90 Nm. Use
Loctite 243.
15.
Position shaft no. 2 in the hole and put the tool over the shaft. To set the distance between
the tilt housing and the upper arm, put two wedges 3HAC 2347-1 in the gap. This is
important so that the pressing force is applied over the tilt housing and the mounted
bearing. Then press the shaft into position (max. pressing force 6 tons).
Product Manual IRB 640
39
Axis 6
Repairs
16.
Remove the wedges and check that there is a gap and that the tilt housing can
move about 1 mm. Use Loctite on the KM nuts and tighten them until the
movement is removed.
N.B. Stop as close to clearance-free as possible. The KM nuts should be tightened
with a spanner 210 degrees to achieve the correct preloading.
17.
Mount covers <15> and <16>.
18.
Refill the bearing house with grease.
19.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
KM-nut, <14>:
90 Nm
7.2 Replacing motor/gear axis 6
Refer to foldout nos. 7 and 9.
It is not necessary to remove the tilt housing from the upper arm.
Dismounting:
1.
Dismount cabling for axis 6.
2.
Drain the grease. Open both magnetic plugs.
3.
Unscrew screws <13>. Dismount shaft <5> with the help of pinscrews M8x65.
4.
Loosen screws <6>.
5.
Free the drive unit and lift it out.
6.
Loosen screws <9/4>. Dismount the gear with the help of 2 screws (M8 holes in
the motor flange).
7.
Loosen screws <9/5>. Dismount the pinion with tool 3HAA 7601-043.
Mounting:
8.
Mount the pinion on a new motor. Use a pin screw, M5x120 with nut, to press
the gear in place. Tighten screw <9/5>, apply Loctite 243.
NOTE!
Be very careful not to tap or hit the shaft axially, nor displace the shaft axially in
any way, as this could give rise to an incorrect air gap in the brake.
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Product Manual IRB 640
Repairs
Axis 6
9.
Mount the gear on the motor <9/4>. Use a new O-ring <9/2>. Turn the gear so
that the screw hole and magnetic oil plug come in the right position. Torque 35
Nm.
10.
Move the sync plates and connector holder on the resolver side over to the new
motor. When replacing the gear, the sync plate <9/11> on the gear is glued.
Clean the surface careful before mounting (a new sync plate must be fitted).
11.
Mount the drive unit in the tilt housing <7/4>.
12.
Mount screws <7/6> and washers <7/7>. Tightening torque 70 Nm.
13.
Mount shaft <7/5>, screws <7/13>, tightening torque 24 Nm.
14.
Pour grease into axis 6 as described in the Maintenance Manual IRB 640.
15.
Calibrate the robot as described in Chapter 9, Calibration.
Tightening torque:
Screw joint motor/gear, 9/4:
Screw joint, drive unit/shaft, 7/13:
Screw joint tilt housing/drive unit, 7/6:
35 Nm
24 Nm
70 Nm
7.3 Checking play in axis 6
Axis 6
1.
Check the play in axis 6 with tool 6896 134-CF.
2.
Measure with a PEK dial indicator against the tool. See Figure 7.
3.
Max. play 0.06 mm at a distance of 190 mm from the centre of axis 6.
Comment: The play in the gear unit cannot be adjusted. If necessary, the gear
unit must be replaced, see Chapter 7.2, Replacing motor/gear axis 6.
190
Axis 6
Figure 7 How to measure the play in the wrist.
Product Manual IRB 640
41
Axis 6
42
Repairs
Product Manual IRB 640
Repairs
Motor units
8 Motor units
8.1 General
Each manipulator axis is provided with a motor unit consisting of:
- A synchronous AC motor
- A brake unit
- A feedback unit.
A gear on the output shaft of the motor forms together with the gear on each axis, the
complete gear unit. Dismounting/mounting of the gear unit is described in an earlier
chapter of this manual.
The electro-magnetic brake is built into the motor unit. The brake is released by a
24 V DC supply. For brake release see Section 7, Installation and Commissioning.
The feedback unit consists of a resolver mounted on the motor shaft and is built into
the motor unit in a similar way as the brake.
Power and signal connections to the motor units are via separate cables between
connections points inside the manipulator and each motor. The cables are connected
to the motor units with connectors.
- The feedback unit is fitted by the motor manufacturer and must never be separated from the motor.
- The communication angle is + 90° (COMOFF=2048).
The motors never need commutating.
- The motor, resolver and brake is to be regarded as an replacement motor unit.
Faulty motor units are repaired by the motor manufacturer at the request of
the ABB Robotics service organisation.
- The cable routing is shown in Figure 8. Note that the signal connection cable
and the power connection cable must not be entwined.
Signal connection
Power connection
Figure 8 Cable routing in the motor unit.
Product Manual IRB 640
43
Motor units
Repairs
8.2 Checking brake performance
Axis
Motor
Static brake
torque (Nm)
Min.
Gear reduction
ratio
1/2/3
3HAB 8278-1
22
185
6
3HAB 5762-1
6
81
A check on the static brake torque for each motor unit can be done by applying a load
on the moving arm or on the turning disc in some suitable way. When calculating the
brake torque, the arm and gear reduction ratio must be taken into consideration. The
coefficient of efficiency for the gear is assumed to be 1.0.
44
Product Manual IRB 640
Repairs
Calibration
9 Calibration
9.1 General
The robot measurement system consists of one feedback unit for each axis and a measurement board that continuously keeps track of the current robot position.
The measurement board memory has a battery backup.
Note! The accumulator unit will be fully recharged when the mains supply has
been on for 36 hrs. without any power interruptions.
If any of the resolver values are changed, the measurement system must be carefully
calibrated (as described in Chapter 9.2, Calibration procedure). This happens when:
- parts affecting the calibration position have been replaced on the robot.
If the contents of the revolution counter memory are lost, the system needs to be
roughly calibrated (as described in Chapter 9.4, Setting the calibration marks on the
manipulator). This may happen when:
- the battery is discharged.
- a resolver error occurs.
- the signal between a resolver and measurement board is interrupted.
- a robot axis has been moved with the control system disconnected.
9.2 Calibration procedure
The axes must be adjusted in increasing sequence, i.e., 1 - 2 - 3 - 5 - 6.
1. Position the manipulator approximately in calibration position 0 as shown Figure
11.
2. Select the MOTORS OFF mode.
Axis 1
3. Remove cover plate on the reference surface on gearbox 1.
4. Attach the synchronisation fixture 6896 0011-YM to the flat surface and insert the
corresponding measuring rod 6896 0011-YN in one of the three holes in the base.
Turn the operating mode selector to MANUAL REDUCED SPEED.
5. Press the enable device on the programming unit and operate the robot manually
with the joystick until the measuring rod is positioned within the flat surface on the
calibration fixture’s elbow.
Be careful! Risk of injury!
Product Manual IRB 640
45
Calibration
Repairs
6. Align the pin and tool with a sliding calliper. See Figure 9.
Sliding calliper
6896 0011-YM
MANIPULATOR
Figure 9 Aligning the pin and tool with a sliding calliper for axis 1.
Before calibrating axes 2, 3 and 6, calibrate the sensors against each other, using a reference
plane surface, in the same direction. See Figure 10.
0000
Reference plane
Sensor
Figure 10 Calibrating the sensors.
Axes 2, 3 and 6
7. Release the enabling device.
8. Mount sensor fixture 6808 0011-GM on the base’s reference plane, see Figure 11.
9. Mount elbow fixture 6808 0011-LP on the lower arm’s calibration plane, see Figure 11.
10. Mount sensor fixture 6808 0011-GM at the back of the upper arm, see Figure 11.
11. Mount sync fixture 3HAC 1904-1 on the frame for axis 6 and turning disc,
see Figure 12.
12. Mount inclination instrument 6807 081-D. One sensor should be mounted on the reference plane and the other on the elbow fixture for axis 2. Both sensors should be positioned in the same direction. See also Figure 11.
Note that the sensor unit must always be mounted on top of the fixture.
46
Product Manual IRB 640
Repairs
Calibration
Axis 3
Tilt housing
Axis 2
View from
above
Sync fixture axis 6,
see Figure 12.
Inclination instrument
6807 081-D
Reference
Axis 3
Axis 6
Aligning the turning disc
Figure 11 Movement directions for calibration, reference surface.
Product Manual IRB 640
47
Calibration
Repairs
Screw
joint
Front view
Side view
Inclination instrument
6807 081-D
Guide hole
From above
Figure 12 Mounting of sync fixture 3HAC 1904-1.
13. Press the enabling device and operate the joystick manually in the directions shown
in the figure on the previous page, until the digital levelling gauge indicates zero.
The gauge should read 0 ±12 increments. (0.3 mm/m).
The reason why the calibration position is always adjusted in the directions shown
in the figure, is that the friction and gravity forces then work together against the
direction of the movement. In this way adjustment is simplified.
48
Product Manual IRB 640
Repairs
Calibration
14. Move the sensor and continue the calibration procedure for the other axes.
15. When all the axes have been adjusted, the resolver values are stored by executing
the following commands on the teach pendant.
16. Press the Misc. window key (see Figure 13).
7
4
1
1
2
8
5
2
0
9
6
3
P2
P1
P3
Figure 13 The Misc. window key from which the Service window can be selected
17. Select Service in the dialog box shown on the display.
18. Press Enter
.
19. Select View: Calibration. The window in Figure 14 appears.
File
Edit
View
Calib
Service Calibration
Unit
Status
1(1)
Robot
Not Calibrated
Figure 14 The window shows whether or not the robot system units are calibrated.
The calibration status can be any of the following:
- Synchronised
All axes are calibrated and their positions are known. The unit is ready for use.
- Not updated Rev. Counter
All axes are fine-calibrated but one (or more) of the axes has a counter that is
NOT updated. That axis, or those axes, must therefore be updated as
described in Chapter 9.4, Setting the calibration marks on the manipulator.
Product Manual IRB 640
49
Calibration
Repairs
- Not calibrated
One (or more) of the axes is NOT fine-calibrated. This or these axes, must
therefore be fine-calibrated as described in Chapter 9.2, Calibration procedure.
20. If there is more than one unit, select the desired unit in the window in Figure 14.
Choose Calib: Calibrate and the window shown in Figure 15 will appear.
Calibration!
Robot
To calibrate, include axes and press OK.
Axis
X
X
X
X
Status
1
2
3
4
5
6
Incl
1(6)
Not Fine Calibrated
Not Fine Calibrated
Fine Calibrated
Not Fine Calibrated
All
Cancel
OK
Figure 15 The dialog box used to calibrate the manipulator.
21. Press the function key All to select all axes, if all axes are to be commutated.
Otherwise, select the desired axis and press the function key Incl (the selected axis
is marked with an x).
22. Confirm by pressing OK. The window in Figure 16 appears.
Calibration!
Robot
- - - - - WARNING - - - - The calibration for all marked axes
will be changed.
It cannot be undone.
OK to continue?
Cancel
OK
Figure 16 The dialog box used to start the calibration.
23. Start the calibration by pressing OK.
An alert box is displayed during calibration.
The Status window appears when the fine calibration is complete. The revolution
counters are always updated at the same time as the calibration is performed.
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Product Manual IRB 640
Repairs
Calibration
Calibration plate and calibration marks
24. Adjust the calibration plates for axes 1, 2, 3 and 6 (see Figure 17).
-
*)
*) axis number
+
Figure 17 Calibration marking.
25. Check the calibration position as described in Chapter 9.5, Checking the calibration
position.
26. Save the system parameters on a floppy disk.
9.3 Aligning the tilt housing
The tilt housing must be aligned after completed calibration of the robot axes,
see Figure 11.
1. Mount sensor fixture 6808 0011-GM on the turning disc, turn the screw around, see
Figure 11.
2. Mount inclination instrument 6807 081-D.
3. Untighten the screw joint for the tilt housing, see Figure 11.
4. Move the tilt housing so that the digital levelling gauge indicates zero. The gauge
should read ±12 increments (0.3 mm/m).
5. Tighten the screw joint again, tightening torque 70 Nm.
6. Check the alignment again.
Product Manual IRB 640
51
Calibration
Repairs
9.4 Setting the calibration marks on the manipulator
When starting up a new robot, you may receive a message telling you that the manipulator is not synchronised. The message appears in the form of an error code on the teach
pendant. If you receive such a message, the revolution counter of the manipulator must
be updated using the calibration marks on the manipulator. See Figure 17.
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’ operation to recharge the battery unit without any power interruptions.
If the resolver values must be calibrated, this should be done as described in the chapter
on Repairs in the IRB 640 Product Manual.
WARNING
Working in the robot work cell is dangerous.
Press the enabling device on the teach pendant and, using the joystick, move the robot
manually so that the calibration marks lie within the tolerance zone (see Figure 22).
Note that axis 6 does not have any mechanical stop and can thus be calibrated at the
wrong faceplate revolution.
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 18).
7
4
1
1
2
P1
8
5
2
0
9
6
3
P2
P3
Figure 18 The Misc. window key from which the Service window can be selected
52
Product Manual IRB 640
Repairs
Calibration
2. Select Service in the dialog box shown on the display.
3. Press Enter
.
4. Then, choose View: Calibration. The window shown in Figure 19 appears.
File
Edit
View
Calib
Service Calibration
Unit
Status
1(1)
Robot
Unsynchronized
Figure 19 This window shows whether or not the robot system units are calibrated.
5. Select the desired unit in the window, as shown in Figure 19.
Choose Calib: Rev. Counter Update. The window in Figure 20 appears.
Rev. Counter Updating!
Robot
To update, include axes and press OK.
Axis
Status
1(6)
X
X
1
2
3
4
5
6
X
X
Incl
Rev counter not updated
Rev counter not updated
Rev counter updated
Rev counter not updated
All
Cancel
OK
Figure 20 The dialog box used to select axes whose revolution counter is 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).
Product Manual IRB 640
53
Calibration
Repairs
7. Confirm by pressing OK. A window like the one in Figure 21 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 21 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 in Chapter 9.5, Checking the calibration position.
-
*)
*) axis number
+
Figure 22 Calibration marks on the manipulator.
10. Save the system parameters on a floppy disk.
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Product Manual IRB 640
Repairs
Calibration
9.5 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 640 on the diskette and follow the instructions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Check
that the calibration marks for each axis are at the same level, see Figure 17. If they are not,
the setting of the revolution counters must be repeated.
Using the Jogging window on the teach pendant:
Open the Jogging window
and choose running axis-by-axis. Using the joystick, move
the robot so that the read-out of the positions is equal to zero. Check that the calibration
marks for each axis are at the same level, see Figure 17. If they are not, the setting of the
revolution counters must be repeated.
9.6 Alternative calibration positions
Before it can be calibrated in one of the two alternative 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 23.
Cal.pos. 2 +90o
Left (1.570796)
Y
Cal.pos. 0
X
Right (-1.570796)
Cal.pos. 1 -90o
Figure 23 Calibration positions 0, 1 and 2 (Normal, Right and Left).
Note!
If the final installation makes it impossible to reach the calibration 0 position, an alternative
calibration position must be set before installation.
Product Manual IRB 640
55
Calibration
Repairs
1. Run the calibration program CAL64 on system disk IRB 2 (SERVICE.DIR\ CALIBRATE.DIR). Select Normal position, check the calibration marks for each axes.
2. Run the calibration program again and select the desired calibration position (Left or
Right), see Figure 23.
3. Change to the new calibration offset for axis 1, as follows:
• Select the window SERVICE;
• View: Calibration;
• Calib: Calibrate;
• Select axis 1 (no other axes)
• Then confirm by pressing OK two times.
4. Change to the new calibration offset on the label, located on the frame to the left of
motor axis 1 (remove the cover between axes 2 and 3). The new calibration offset values
can be found as follows:
• Select the window SYSTEM PARAMETERS;
• Types: Motor;
• Select axis 1;
• Press Enter
• Note the Cal offset value.
5. Change to the new calibration position on axis 1, as follows:
• Select the window SYSTEM PARAMETERS;
• Topics: Manipulator;
• Types: Arm;
• Select axis 1;
• Change Cal pos to 1.570796 or -1.570796 depending on selected calibration position. The angle is in radians, see Figure 23.
6. Restart the robot by selecting File: Restart.
7. Move the sync.plate, on the base, for axis 1 to its new position.
8. Save the system parameters on a floppy disk.
56
Product Manual IRB 640
Repairs
Calibration
9.7 Calibration equipment
1. Inclination instrument
6807 081-D
2. Calibration equipment
6808 011-GM
6896 011-YM
6896 0011-YN
6808 0011-LP
3HAC 1904-1
Sensor fixture
Sync fixture axis 1
Measuring rod
Angle bracket
Sync fixture, axis 6
3HAA 0001-UA
3HAA 0001-XR
X= -15 mm, Z= -150 mm
Calibration tools for TCP check
Tool for TCP adjustment
Calibration set for Opti Master
Product Manual IRB 640
57
Calibration
58
Repairs
Product Manual IRB 640
Repairs
Special Tools List
10 Special Tools List
Tools marked with an * are used for service at more than one place.
The need for special tools has been reduced to a minimum. When tools are needed for
dismounting/mounting work, a description is given in the Product Manual, Chapter
Repairs.
During the ordinary service training courses arranged by ABB Flexible Automation,
detailed descriptions of the tools are given together with their use.
Axis 1
Guide pins, 2
M12x200
Guide pins
M12x300
Rotating gear, axes 1, 2 and 3
3HAC 0266-1
Lifting device for bearing axis 1
6896 134-XD
Lifting tool, motor axis 1
3HAB 7396-1
Axis 2
Auxiliary shaft
3HAB 6558-1
Auxiliary shaft
3HAB 6567-1
Screw for locking axis 2
M16x150
Tubular KM socket
4-KM 8
Pressing tool bearing, lower arm
6896 134-FJ
Lifting gear axes 2 and 3, chain hoist
6896 0011-YL
Tool for guiding ring assembly
3HAC 0879-1
Axis 3
Hydraulic cylinder
NIKE CLF 50-10
Distance, support bearing parallel arm
M16x60
Pressing tool, bearing and seal, parallel bar
6896 134-FM
Lifting gear axes 2 and 3, chain hoist
6896 0011-YL
Axis 6
Nipple
SKF 101 8219
Puller gear motor axis 6
3HAA 7601-043
Play measurement tool, wrist
6896 134-CE
Play measurement tool, wrist
6896 134-CD
Product Manual IRB 640
59
Special Tools List
Repairs
Tool for dismounting shafts
3HAC 2486-1
Pressing tool for shafts
3HAC 0902-1
Play measurement tool, wrist
6896 134-CF
Tightening tool
3HAB 1022-1
Miscellaneous
Pressing tool, support bearing/seal
6896 134-FR/-FP
Pull rod
6896 134-FH
Dismounting bearing and sealing, p-rod
3HAB 7806-1
Grease nipples (R 1/8”)
2545 2021-26
Calibration tool for TCP check
Tools for grease replacement, axes 1-3
Axis 1
Socket
3HAB 1561-1
Nipple
3HAA 7601-090
Hose
D=18/12 mm, L=1000 mm
Hose clip
D=15-20 mm
Socket
Square 1/2” / hexagon 10 mm
Extender
1/2” / L=250 mm
Ratchet wrench
Axis 2-3, 6
60
Nipple
3HAA 7601-091
Hose
D=18/12 mm, L=1000 mm
Allen key
6 mm
Product Manual IRB 640
Repairs
Special Tools List
Tilt house
Mounting of sealing
3HAC 0905-1
Lifting the tilt house with motor
3HAC 1060-1
Upper rod
Pressing tool for needle bearing
3HAC 1388-1
Lower rod/Link
Mounting of bearing
3HAC 2241-1
Pressing tool for bearing
3HAC 0906-1
Pressing tool for sealing
3HAC 2226-1
Pressing tool for sealing
3HAC 2227-1
Pressing tool for bearing
3HAC 4315-1
Pressing tool for sealing
3HAC 4316-1
Pressing tool for sealing
3HAC 4317-1
Tilthouse/Upper arm
Distance when mounting bearing
3HAC 2984-1
Wedge for adjustment of tilt house/upper
arm
3HAC 2347-1
Pressing tool for shaft
3HAC 3409-1
Ratchet wrench, socket 4 - KM8, graduated
arc
Tool for dismounting bearing in tilt house
Inner expanded socket
Standard pullet
Dismounting of axis/tilt house
Puller
Product Manual IRB 640
3HAC 2486-1
61
Special Tools List
62
Repairs
Product Manual IRB 640
Spare Parts
CONTENTS
Page
1 Manipulator ............................................................................................................. 2
1.1 IRB 640 ........................................................................................................... 2
1.2 Axis 1, complete ............................................................................................. 5
1.3 Base................................................................................................................. 7
1.4 Frame, complete.............................................................................................. 8
1.5 Axes 2 and 3.................................................................................................... 9
1.6 Lower arm ....................................................................................................... 11
1.7 Upper arm ....................................................................................................... 12
1.8 Parallel rod ...................................................................................................... 13
1.9 Drive unit axis 6.............................................................................................. 14
1.10 Cooling device axis 1.................................................................................... 15
1.11 Cabling .......................................................................................................... 15
1.12 Position switches, axes 1 and 2..................................................................... 15
1.13 Signal lamp ................................................................................................... 16
1.14 Customer vacum set ...................................................................................... 16
2 Control system ......................................................................................................... 17
2.1 Mains power.................................................................................................... 17
2.2 Operators panel ............................................................................................... 17
2.3 Computer unit ................................................................................................. 18
2.4 I/O units........................................................................................................... 18
2.5 Drive system ................................................................................................... 19
2.6 Teach pendant, TPU 2 ..................................................................................... 19
2.7 Contactor unit.................................................................................................. 19
2.8 Miscellaneous.................................................................................................. 19
Product Manual IRB 640
1
Spare Parts
Spare Parts
1 Manipulator
Item numbers refer to item numbers on the foldouts.
1.1 IRB 640
Itm Qty
Name
Art. no.
Rem
1
Mtrl set axis 1
Mtrl set axis 1
Mtrl set axes 2 and 3
Manipulator, mtrl set complete
Mtrl set
Balancing unit
Circlip
Guiding ring
Adjust. needle bearing
Sealing ring
Ring
Support washer
Lock nut
Lift device for fork lift
Screw
Washer
Lifting device
Lifting device
Instruction plate
Fan
Clip lock
Cover with gasket
Distance screw
Mounting base, outdoors
Measure card unit
Torx pan head roll. screw
Cover
Cap
Taper roller bearing
Sealing ring
Nilos ring
3HAC 4325-1
3HAC 4326-1
3HAC 4324-1
3HAC 1215-1
3HAB 4217-1
3HAB 5971-1
3HAB 6178-1
3HAB 6176-1
3HAB 6432-1
3HAB 6254-1
3HAB 6275-1
3HAB 6279-1
3HAB 6271-1
3HAA 0001-SY
3HAB 3409-93
3HAA 1001-186
3HAB 4229-1
3HAB 4230-1
3HAB 4232-1
3HAC 2306-1
5217 520-11
3HAA 0001-ZK
2125 0442-1
2166 2058-2
3HAB 4259-1
9ADA 629-56
3HAA 0001-SZ
3HAA 1001-199
2213 3802-8
2216 264-16
2216 0085-5
CP/CS
CP/CS, CAN
2
3
50
50.1
50.1.1
50.1.2
50.1.3
50.2
50.3
50.4
50.5
60
1
1
1
2
4
2
4
2
8
8
2
2
4
70
109
112
114
115
119
120
121
122
133
134
135
10
1
20
3
1
37
1
1
2
2
2
Product Manual IRB 640
Type B
Not shown
Not shown
Not shown
M16x60 12.9
17x30x3
See 1.10
17x11.1
M6x16
32013X
65x98.4x6.3
2
Spare Parts
136
137
138
139
140
145.x
146
149
154
155
159
163
166
167
169
170
171
172
176
177
178
182
183
202
203
620
2
2
1
2
2
1
1
1
2
2
1
2
6
3
2
2
1
1
6
1
1
1
1
4
4
1
620
620
620
630
640
2.214
2.179
2.180
1
1
1
1
Lock nut
Set screw, cup point
Spacer
Spacer
Sealing ring
Lables IRB 640
Battery unit
Cable straps, outdoors
Protective plate
Torx counters roll. screw
Locking liquid
Grease tube
Sealant
Torx pan head roll. screw
Lubricating grease
Locking liquid
Grease
Torx pan head roll. screw
Torx pan head roll. screw
Washer
Guide for cabling
Cover
Torx pan head rol. screw
Shaft
Shaft lower arm
Limited working range
Stop arm
Hexagon head screw
Plain washer
Erection provision
Limited working range
2126 2851-112
9ADA 205-75
3HAA 1001-125
3HAA 1001-126
3HAA 1001-173
3HAC 2103-1
4944 026-4
2166 2055-4
3HAA 1001-164
9ADA 633-55
1269 0014-410
3HAA 1001-716
1269 1907-1
9ADA 629-59
1171 4013-301
1269 0014-409
3HAC 2331-1
9ADA 629-57
9ADA 629-63
2151 2082-150
3HAA 1001-721
3HAA 1001-161
9ADA 629-55
3HAA 1001-127
3HAC 1208-1
3HAB 4224-1
3HAB 4533-1
9ADA 120-77
9ADA 313-5
3HAB 4223-1
3HAB 4225-1
Limited working range
Limited working range
Pos switch axis 1
Pos switch axis 1
Pos switch axis 1
Pos switch axis 2
Motor aixs 2/3
Stop
Washer
3HAB 4087-1
3HAB 4087-1
3HAC 1031-1
3HAC 1031-2
3HAC 1031-3
3HAC 3732-1
3HAB 8278-1
3HAA 10001-89
3HAA 1001-632
Product Manual IRB 640
M60x2
M10x20
4.8x290
M6x12
Loctite 243 1 ml
Loctite 577 1 ml
M6x30
EP-grease
Loctite 290 1 ml
Molywhite 1300 ml
M6x20
M6x50
6.1x20x2
M6x12
option 621
M16x50 8.8
17x30x3
option 621, 622 and
623
option 622
option 623
1 switch
2 switches
3 switches
3
Spare Parts
2.181
1
Hex socket head cap screw
3HAB 7700-69
3.107
3.120
3.142
1
37
4
Parallel rod, complete
Torx pan head roll. screw
Hex socket head cap screw
3HAA 0001-ER
9ADA 629-56
3HAB 3409-86
3.143
3.160
12
8
Washer
Hex socketnhead cap screw
3HAA 1001-186
3HAB 3409-88
3.201
3.204
205
1
1
Upper arm, complete
Balancing weight
Linkage, complete
3HAC 1217-1
3HAC 1738-1
3HAC 1219-1
Upper rod
Adjust. needle bearing
Sealing ring
Ring
Support washer
Lock nut
Locking liquid
Lubricating grease
Lower rod
Spherical roller bearing
Sealing, without dust lip
VK-cover
Lubricating grease
Sealing ring without dust lip
Support washer
Hex socket head cap screw
Retaining ring, bore
Ring
Friction washer
Link machining
Taper roller bearing
Sealing ring without dust lip
Lock nut
Locking liquid
Grease
VK-cover
Support ring
Plug
3HAC 1051-1
3HAB 6432-1
3HAB 6254-1
3HAB 6275-1
3HAB 6279-1
3HAB 6271-1
1269 0014-410
1171 4012-201
3HAC 1050-1
3HAA 2167-11
3HAB 3702-14
3HAA 2166-11
1171 4012-201
3HAB 3702-18
3HAC 2627-1
9ADA 183-65
9ABA 137-31
3HAC 1643-1
3HAB 9363-1
3HAC 0661-1
3HAA 2103-18
3HAB 3702-29
2126 2851-107
1269 0014-410
3HAC 2331
3HAA 2166-11
3HAC 1717-1
2529 1920-2
205.1
205.2
205.3
205.4
205.5
205.6
205.7
205.8
205.20
205.21
205.22
205.24
205.26
205.27
205.28
205.29
205.30
205.31
205.32
205.40
205.41
205.42
205.43
205.44
205.45
205.46
205.47
205.48
1
1
2
4
2
4
4
1
2
2
1
1
1
1
2
2
1
1
2
1
1
1
1
2
Product Manual IRB 640
M12x50 12.9
Unbrako
Gleitmo 610
M6x16
M16x60
Gleitmo 610
M16x70
Gleitmo 610
413 kg
Loctite 243 1 ml
1g
D=80 B=10
D=52/68 B=8
M13x30 8.8
80
40/75-26
M35x1.5
Loctite 243 2 ml
Molywhite
D=80 B=10
R1/8”
4
Spare Parts
1.2 Axis 1, complete
Itm Qty
Name
Art. no.
Rem
1
1
1
1
1
5
15
Axis 1, complete
Axis 1, complete
Frame, complete
Base, complete
Brake release unit
Screw
Screw
3HAC 4325-1
3HAC 4326-1
3HAC 1220-1
3HAC 3806-1
3HAA 0001-ADY
9ADA 629-56
3HAB 3409-73
CP/CS
CAN
15
1
1
Washer
Locking fluid
Screw
Plain washer
Motor
O-ring
Sealant
Friction ring
Screw
3HAA 1001-632
1269 0014-410
9ADA 183-50
9ADA 312-8
3HAB 8278-1
2152 0431-17
1269 1907-1
3HAA 1001-613
3HAB 3409-62
22
23
13
5
1
1
1
1
1
Sealing compound
Screw
Plain washer
Symbol
Base cabling
Base cabling
Cover with gasket
Hex socket head cap screw
1236 0012-202
9ADA 629-57
9ADA 312-6
3HAB 5617-1
3HAC 3766-1
3HAC 3880-1
3HAA 1001-700
3HAB 3409-62
24
25
26
27
28
29
30
31
32
33
34
1
2
2
1
1
4
4
1
1
1
1
Protective hood
Screw
Plain washer
Sync. bracket
Sync. plate axis 1
Screw
Plain washer
Bracket
Sync. plate nonie
Protective plate
Screw
2522 2101-15
9ADA 183-40
9ADA 312-7
3HAB 4649-1
3HAA 1001-73
9ADA 629-32
9ADA 312-4
3HAB 4648-1
3HAA 1001-79
2155 187-11
2121 0596-31
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
4
4
1
1
Product Manual IRB 640
M6x16
M12x70 12.9
Gleitmo 610
13x24x2.5
Loctite 243, 1 ml
M10x25
10.5x22x2
234.54x3.53
Loctite 577, 10 ml
M10x100 12.9
Gleitmo 610
Permatex3, 1 ml
M6x20
6.4x12x1.6
Earth sign
CP/CV, CAN
SW2, CP/CV, CAN
M10x100 12.9
Gleitmo 610
D=17.2-20
M8x40 8.8
8.4x16x1.6
M4x8
4.3x9x0.8
M8x12 10.9
5
Spare Parts
41
42
43
7
1
3
Straps
Holder
Screw
2166 2055-3
3HAA 1001-668
3HAB 7700-94
44
45
3
3
Spring washer
Screw
3HAA 1001-181
3HAB 7700-84
46
47
48
49
3
1
1
18
Support washer
Axis 2 cabling
Axis 3 cabling
Screw
3HAA 1001-200
3HAC 0703-1
3HAB 8737-1
9ADA 618-55
Product Manual IRB 640
L=208
M16x140 12.9
Unbrako
M12x140 12.9
Unbrako
12.5x24x5.9
M6x12 8.8
6
Spare Parts
1.3 Base
Itm Qty
Name
Art. no.
1
2
3
5
6
8
Base, complete
Base
Bottom plate
Cable guide rail
Stop shaft
Screw
Angle
3HAC 3806-1
3HAC 0517-2
3HAA 1001-695
3HAA 1001-691
3HAB 4082-1
9ADA 618-56
3HAA 1001-154
1
1
1
1
8
2
Product Manual IRB 640
Rem
M6x16 8.8
7
Spare Parts
1.4 Frame, complete
Itm Qty
Name
Art. no.
1
2
3
1
1
1
15
Frame, complete
Frame
Bearing
Screw
3HAC 1220-1
3HAC 1800-1
3HAA 1001-1
3HAB 3409-73
4
5
6
23
1
8
Washer
Plug
Hex socket head cap screw
3HAA 1001-632
2522 2021-113
3HAB 3409-75
11
12
13
14
1
1
1
1
O-ring
Reduction gear
Friction ring
Cover
2152 0431-15
3HAC 0665-1
3HAA 1001-614
3HAB 6130-1
Product Manual IRB 640
Rem
M12x70 12.9
Gleitmo 610
KR 1/2”
M12x90 12.9
Gleitmo 610
245.0x3.0
8
Spare Parts
1.5 Axes 2 and 3
Itm Qty
Name
Art. no.
1
2
1.3
1.4
1.5
2
2
6
Material set, axes 2 and 3
Manipulator material set, complete
Reduction gear
O-ring
Screw
3HAC 4324-1
3HAC 1215-1
3HAB 4226-1
2152 0431-17
3HAB 7700-80
1.6
1.7
6
6
Support washer
Screw
3HAA 1001-200
3HAB 7700-94
1.9
1.14
1.16
1.28
1.29
1.30
6
2
2
2
2
2
Spring washer
O-ring
Friction ring
O-ring
Motor, axis 2,3
Screw
3HAA 1001-181
2152 2012-550
3HAA 1001-616
2152 2012-437
3HAB 8278-1
3HAB 3409-62
1.31
1.32
1.33
1.34
1.35
1.37
1.38
1.38.1
1.38.2
1.38.3
1.39
1.39.1
1.39.3
1.39.5
1.39.6
1.39.7
2.3
2.4
2.112
2.114
2.115
2.116
8
8
4
Screw
Plain washer
Magnetic plug
Grease
Washer
Friction ring
Motor socket, mtrl kit
Motor socket
Screw
Washer
Sync. plates
Bracket for sync. plate
Sync .plate with nonie
Screw
Plain washer
Screw
Brake release unit
Screw
Cover
Screw
Mounting base
Screw
9ADA 183-50
9ADA 312-8
2522 122-1
3HAC 2331-1
2152 0441-1
3HAA 1001-613
3HAB 4193-1
3HAB 4056-1
3HAB 3409-74
3HAA 1001-632
3HAA 0001-SU
3HAA 1001-104
3HAA 1001-79
9ADA 618-31
9ADA 312-4
9ADA 618-55
3HAA 0001-ADY
9ADA 629-56
3HAA 0001-ZK
2125 0442-1
2166 2058-2
9ADA 618-23
4
2
2
16
16
1
1
1
4
4
4
1
13
1
20
3
3
Product Manual IRB 640
Rem
RV-250AII
234.54x3.53
M12x140 12.9
Gleitmo 610
12.5x24x5.9
M16x140 12.9
Gleitmo 610
269.3x5.7
124.5x3
M10x100 12.9
Gleitmo 610
M10x25 8.8
10.5x20x2
1/4”
Molywhite
13.5x18x1.5
M12x80 12.9
13x21x2
M4x6
4.3x9x0.8
M6x12
M6x16
17x11,1
M3x8 8.8
9
Spare Parts
2.117
2.119
2.119.1
2.120
2.121
2.146
2.163
2.167
2.172
2.178
3
1
1
29
1
1
1
2
3
1
Nut
Measuring card unit
Serial measurement board
Screw
Cover
Battery pack
Grease tube
Screw
Screw
Guide for cabling
Product Manual IRB 640
9ADA 267-3
3HAB 4259-1
3HAB 2213-1
9ADA 629-56
3HAA 0001-SZ
4944 026-4
3HAA 1001-716
9ADA 629-59
9ADA 629-57
3HAA 1001-721
M3 8
DSQC 313
M6x16 8.8
M6x30
M6x20
10
Spare Parts
1.6 Lower arm
Itm Qty
Name
Art. no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Lower arm system
Lower arm
Parallel arm
Spherical roller bearing
Spacing sleeve
Set screw
Damper
Damper
Screw
Washer
Damper
Support plate
Screw
Damper
Screw
Plain washer
Sealant
Locking fluid
3HAB 4167-1
3HAB 4168-1
3HAC 1110-1
3HAB 4169-1
3HAB 4387-1
2122 2765-99
3HAA 1001-81
3HAA 1001-123
9ADA 183-37
9ADA 312-7
3HAA 1001-90
3HAA 1001-282
2121 2763-364
3HAA 1001-622
9ADA 618-56
9ADA 312-6
1269 1907-1
1269 0014-410
1
1
2
2
2
2
2
4
4
1
1
2
2
4
4
Product Manual IRB 640
Rem
M20x20
M8x25
8.4x16x1.6
M6x10
M6x16
6.4x12x1.6
Loctite 577, 1 ml
Loctite 243, 1 ml
11
Spare Parts
1.7 Upper arm
Itm Qty
Name
Art. no.
1
2
3
4
5
6
1
4
1
1
1
12
Upper arm complete
Upper arm, machining
Plug
Tilt house, machining
Drive unit axis 6
Shaft tilt house
Hex socket head cap screw
3HAC 1217-1
3HAC 2888-1
2529 1920-2
3HAC 3010-1
3HAB 6828-1
3HAC 1210-1
3HAB 3409-50
7
8
12
6
Plain washer
Hex socket head cap screw
3HAC 1315-1
3HAB 3402-37
9
10
11
12
13
14
15
16
17
18
19
20
21
2
2
2
Shaft upper arm
Sealing ring without dust lip
Taper roller bearing
Lubricating grease
Locking liquid
Lock nut
VK-cover
VK-cover
Cabling upper front c.-conn.
Bracket motor 6
Toex pan head roll. screw
Plastic cover
Torx pan head roll. screw
3HAC 2887-1
3HAB 3701-23
3HAB 3729-14
1171 4012-201
1269 0014-410
2126 2851-108
3HAA 2166-17
3HAA 2166-20
3HAC 0710-1
3HAC 1087-1
9ADA 629-54
3HAC 1854-1
9ADA 629-59
2
2
2
1
1
12
1
4
Product Manual IRB 640
Rem
R1/8”
M10x40 12.9
Gleitmo 610
M8x25 8.8
Gleitmo 610
D=48/62 B=8
D=40/90 B=23
5g
Loctite 243 5 ml
M40x1.5
D=19 B=6
D=90 B=8
M6x10
M6x30
12
Spare Parts
1.8 Parallel rod
Itm Qty
Name
Art. no.
Rem
1
2
3
4
5
6
7
Parallel rod
Parallel rod
Shaft
Ring
Spherical bearing
Adapter sleeve
Retaining ring
Lubricating grease
3HAA 0001-ER
3HAA 1001-71
3HAA 1001-88
3HAA 1001-86
3HAA 1001-189
2213 1905-21
9ADA 137-33
1171 4012-201
40 g
1
2
4
2
2
2
Both ends identical
Product Manual IRB 640
13
Spare Parts
1.9 Drive unit axis 6
Itm Qty
Name
Art. no.
1
2
3*
3.3
4
5
6
7
8
9
10
11
12
13
14
15
Drive unit axis 6
Motor
O-ring
Reduction gear
Pinion
Hexagon cap screw
Hexagon cap screw
Washer
Magnetic plug
Washer
Sync. plate axis 5
Sync. plate axis 6
Sync. plate with nonie
Six point socket screw
Plain washer
Grease
Locking fluid
3HAB 6828-1
3HAB 5762-1
2152 0431-12
3HAB 5593-1
3HAA 1001-522
3HAB 3409-40
9ADA 183-21
3HAA 1001-172
2522 122-1
2152 0441-1
3HAA 1001-77
3HAA 1001-78
3HAA 1001-174
9ADA 629-32
9ADA 312-4
3HAC 2331-1
1290 014-410
1
1
1
1
8
1
8
1
1
1
1
1
4
4
Rem
151.99x3.53
ERV-30A-81
RV-30E-81
M8x40 12.9
M5x50 8.8
8.4x13x1.5
R 1/4”
13.5x18x1.5
M4x8
4.3x9x0.8
Molywhite 300 ml
Loctite 243 1 ml
* when exchanging the reduction gear a new item 11 must be fitted
Product Manual IRB 640
14
Spare Parts
1.10 Cooling device axis 1
Itm Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
1
1
4
1
1
2
1
4
1
1
1
1
1
1
4
1
Name
Art. no.
Cooling axis 1
Radial fan
Screw
Gasket
Bracket
Gasket
Flange
Nut
Cover
Screw
Holder
Cover
Fan cabling
Cable gland
Air filter
Sealing plug
3HAC 2306-1
3HAA 0001-UL
9ADA 618-56
3HAA 1001-607
3HAB 5882-1
3HAB 6968-1
3HAA 1001-605
9ADA 267-6
3HAC 2341-1
9ADA 618-61
3HAC 2342-1
3HAA 0001-VH
3HAA 0001-ACE
3HAB 6509-7
3HAA 1001-612
2522 253-2
Rem
M6x16 8.8
M6 8
M6x40 8.8
Pr 18.6
Pr 18.6
1.11 Cabling
21
1
Base cabling
3HAC 3766-1
21
1
Base cabling
3HAC 3880-1
47
48
17
1
1
1
Axis 2 cabling
Axis 3 cabling
Cabling upper front
3HAC 0703-1
3HAB 8737-1
3HAC 3953-1
17
12
1
1
Cabling upper front
Fan cabling
3HAC 3954-1
3HAA 0001-ACE
See section 1.2
CP/CS
See section 1.2
CP/CS, CAN
See section 1.2
See section 1.2
See section 1.7
CP/CS
CAN
See section 1.10
1.12 Position switches, axes 1 and 2
Spare part list for position switches on axes 1 and 2 is supplied if the option is ordered.
Product Manual IRB 640
15
Spare Parts
1.13 Signal lamp
Itm Qty
Name
Art. no.
Rem
3HAC 3736-1
3HAC 2552-1
3HAC 2987-1
3HAB 3772-21
3HAC 3629-1
3HAB 6509-2
9ADA 629-54
Foldout 11
1
2
3
4
5
6
Signaler lamp
Lamp
Lamp holder
O-ring
Bracket signal lamp
Cable gland (tabular dr.)
Torx pan head roll. screw
Rem
1
1
1
1
1
1
1.14 Customer vacum set
Itm Qty
Name
Art. no.
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Customer vacum, complete
Cover with gasket
Cover with gasket
Cust. power vaccuum, R1-R2
Sealing gasket
Torx pan head screw
Dust cap
Contactholder
Cable straps, outdoors
Earth symbol
Torx pan head roll. screw
Plain washer
Single-core cable
Cable lug
Cust. power vaccuum, R3-R4
Cable gland
Sealing plug
Receptacles for pin 23p
Keying pin
Bag
Document set (CPV)
Plate: Max. pressure
Plate: Cust. power vac.
3HAC 2127-1
3HAB 7748-1
3HAC 2128-1
3HAC 2130-1
2152 0363-5
9ADA 618-23
3HAA 1001-630
3HAB 4132-1
2166 2055-3
3HAB 5617-1
9ADA 629-42
9ADA 312-5
9ADA 103-35
9ADA 219-11
3HAC 2132-1
3HAB 7417-1
2522 253-2
3HAA 2599-3
5217 649-29
2969 105-11
3HAC 3236-1
3HAC 4242-1
3HAC 2776-1
1
1
1
1
4
1
1
1
1
5
3
0.8
2
1
1
3
1
1
1
1
1
1
Product Manual IRB 640
16
Spare Parts
2 Control system
Item numbers refer to detailed circuit diagram, see chapter Circuit Diagram.
2.1 Mains power
Itm Qty
Name
Art. no.
Rem
Z1
Mains filter
Mains filter
3HAB 9627-1
3HAC 1477-1
16 A
25 A
Q1
Rotary switch
Door interlock
3HAB 5142-1
3HAB 9677-1
Option 141
Part of opt. 142
F1
Circuit breaker
Circuit breaker
3HAB 2017-4
3HAB 2017-7
opt. 147, 16 A
opt. 149, 25 A
T1
Transformer unit 200-400 V
Transformer unit 400-500 V
Transformer unit 475-600 V
3HAC 0754-1
3HAC 0755-1
3HAC 0756-1
T3
T3
T3
T1, F1
Automatic fuse drive system
3HAC 0870-1
20 A
T1, F2
Automatic fuse power supply
3HAC 0871-1
10 A
T1, FU1
T1, FU2
Fuse 6.3 A
Fuse 3.15 A
5672 817-22
5672 817-19
slow, 5x20 mm
slow, 5x20 mm
Rem
2.2 Operators panel
Itm Qty
Name
Art. no.
S1.1
Cam switch key
Cam switch (operat. mode selector)
Cam switch (operat. mode selector)
3HAB 8868-1
3HAC 2349-1
3HAC 3116-1
S1.2
Motor ON button
Lamp block
Contact block
Glow lamp
3HAB 7818-1
SK 616 003-A
SK 616 001-A
5911 069-10
S1.3
Emergency stop button
Emergency stop block
3HAB 5171-1
3HAB 8230-1
P1
Duty time counter
3HAC 0420-7
24 VDC
D1
Disk drive
Disk drive ribbon cable
Disk drive power cable
Cover with cooler
3HAB 2480-1
3HAB 7420-1
3HAB 7421-1
3HAB 7239-3
opt. 472
Product Manual IRB 640
opt. 193, Auto/Man
opt. 191,
Auto/Man/100%
17
Spare Parts
2.3 Computer unit
Itm Qty
Name
Type no.
Art. no.
G1
Power supply 24V/6A
Power supply 24V/7.5A
DSQC334
DSQC374
3HAB 5845-1
3HAC 3462-1
G2-3
2
Battery
Rem
3HAB 2038-1
A31
Robot computer -3.1
Robot computer -3.2
DSQC363
DSQC373
3HAC 1462-1
3HAC 3130-1
A41
Memory board 8 Mb
Memory board 16 Mb
DSQC323
DSQC324
3HAB 5956-1
3HAB 5957-1
A51
Main computer 25 MHz 3.1 DSQC361
3HAC 0373-1
A71
Network I/O computer
3HNE 00001-1 opt. 292
A82
Back plane
DSQC330
Back plane (for X-capacity) DSQC369
3HAB 6372-1
3HAC 2424-1
Wrist band
3HAB 2997-1
DSQC336
2.4 I/O units
Itm Qty
Name
Type no.
Art. no.
A81
Panel unit
DSQC331
3HAB 7215-1
I/O1-04
Digital I/O unit
Combi I/O unit
Analog I/O unit
Relay I/O unit
120 VAC I/O unit
Remote I/O unit
Interbus-S slave
Profibus DP slave
Encoder interface unit
DSQC328
DSQC327
DSQC 355
DSQC 332
DSQC 320
DSQC350
DSQC 351
DSQC 352
DSQC 354
3HAB 7229-1
3HAB 7230-1
3HNE 00554-1
3HAB 9669-1
3HAB 7231-1
3HNE 00025-1
3HNE 00006-1
3HNE 00009-1
3HNE 00065-1
I/O 1-2
Mounting kit I/O 1-2
3HAB 7216-1
I/O 1-2
CAN cable I/O 1-2
3HAC 0200-1
I/O 1-4
Mounting kit I/O 1-4
3HAB 7636-1
I/O 1-4
CAN cable I/O 1-4
3HAB 7418-1
incl. in kit
XT31
24V I/O supply fuse 2 A
5617 817-17
Slow, 5x20 mm
Product Manual IRB 640
Rem
opt. 20x
opt. 23x
opt. 22x
opt. 26x
opt. 25x
opt. 281
opt. 284
opt. 286
opt. 288
incl. in kit
18
Spare Parts
2.5 Drive system
Itm Qty
Name
Type no.
Art. no.
A0
1
DC link DC3
DSQC345D
3HAB 8101-4
A1-2
2
Drive unit GT
DSQC346G
3HAB 8101-8
E1-4
2, 4 Drive unit fan
3HAB 7311-1
1
Complete fan unit
3HAB 7362-1
Brake resistor
3HAB 9165-1
Air filter (in front door)
3HAC 0927-1
R1.1-4 4
Rem
47 Ohm,
200 W
2.6 Teach pendant, TPU 2
Itm Qty
Name
Art. no.
Rem
Complete unit
3HNE 00313-1 With backlight
Complete unit
3HNE 00314-1 Standard,
without backlight
Extension cable
3HNE 00133-1 10 m
2.7 Contactor unit
Itm
Qty
Name
Art. no.
K1, K2
2
Motor On contactor
3HAB 8757-1
K3
1
Brake contactor
3HAB 8757-1
R2-3
2
DC-link inrush current limiter
3HAC 0977-1
Rem
10 Ohm, 50 W
2.8 Miscellaneous
Itm Qty
Name
Art. no.
Rem
Cable, measurement 7 m
3HAC 2493-1
Option 651
Cable, motor 7 m
3HAC 2512-1
Option 651
Cable, measurement 15 m
3HAC 2534-1
Option 652
Cable, motor 15 m
3HAC 2535-1
Option 652
Cable, measurement 22 m
3HAC 2540-1
Option 653
Cable, motor 22 m
3HAC 2560-1
Option 653
Cable, measurement 30 m
3HAC 2566-1
Option 654
Product Manual IRB 640
19
Spare Parts
Cable, motor 30 m
3HAC 2572-1
Option 654
XP5, XP6
Customer cable, power-signal 7 m
3HAC 2121 -1
Option 671
XP5, XP6
Customer cable, power-signal 15 m
3HAB 7143-1
Option 672
XP5, XP6
Customer cable, power-signal 22 m
3HAC 2125-1
Option 673
XP5, XP6
Customer cable, power-signal 30 m
3HAC 2126-1
Option 674
XP8
Cable pos. switch 7 m
Cable pos. switch 15 m
Cable pos. switch 22 m
Cable pos. switch 30 m
3HAC 3378-1
3HAC 3379-1
3HAC 3380-1
3HAC 3381-1
Option 71
Option 72
Option 73
Option 74
Product Manual IRB 640
20