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1 Introduction / System Description 2 Product Specifications 3 Safety 4 Certificates 5 Configuration list 6 Fault tracing guide 7 Decomissioning 8 Description 9 Installation and Comissioning 10 Maintenace and Repairs 11 Spare Parts List 12 Circuit Diagram 13 Installation and Comissioning 14 Maintenance 15 Repairs 16 Spare Parts List 17 Circuit Diagram 18 Special Equipment for this Robot 19 Common Chapters 3HAC 7677-1 M2000 / Rev. 1 Product Manual IRB 6400R Controller Manipulator

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13HAC 7677-1 M2000 / Rev. 1

Introduction / System Description Product Specifications Safety Certificates Configuration list Fault tracing guide Decomissioning Description Installation and Comissioning Maintenace and Repairs Spare Parts List Circuit Diagram Installation and Comissioning Maintenance Repairs Spare Parts List Circuit Diagram

Common Chapters Controller Manipulator

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Product Manual IRB 6400R

18 Special Equipment for this Robot 19

IntroductionCONTENTSPage 1 Introduction ....................................................................................................... 3 1.1 How to use this Manual ............................................................................. 3 1.2 What you must know before you use the Robot........................................ 3 1.3 Identification .............................................................................................. 4 1.4 Structure.................................................................................................... 6 1.4.1 Manipulator...................................................................................... 6 1.4.2 Controller ......................................................................................... 10 1.4.3 Electronics unit ................................................................................ 10

Product Manual

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2

Product Manual IRB 140

Introduction 1 Introduction1.1 How to use this ManualThis manual provides information on installation, preventive maintenance, troubleshooting, and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance training course offered by ABB Flexible Automation. Anyone reading this manual should also have access to the Users 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 Users Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults. Servicing and maintenance routines are described in the chapter on Maintenance.

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

All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone. Product Manual 3

Introduction

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

ABB Robotics Products ABS-721 68 Vsters Sweden Made in Sweden Type: Robot version: Man. order: Nom. load Serial. No: Date of manufacturing: Net weight 2,5.120 : 2060 kg 2.5-150 : 2060 kg 2,5-200 : 2230 kg IRB 6400R M2000 IRB 6400R/2.5-150 XXXXXX See instructions 6400R-XXXX 2000-XX-XX 2,8-150 : 2240 kg 2,8-200 : 2390 kg 3.0-100 : 2250 kg

Identification plate showin the IRB 6400R / M2000

IRB 140(0)

IRB 2400

IRB 4400

IRB 6400R

IRB 640

IRB 340

IRB 140

IRB 840/A

4

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

Product Manual

Introduction. ABB Robotics Products ABS-721 68 Vsters Sweden Made in Sweden

Type: Robo t versi on: Volta ge: 3 x 400 V PoweFigure 2 Identification plate on the controller.

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

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

Product Manual

5

Introduction1.4 Structure ManipulatorThe robot is made up of two main parts, the manipulator and controller. The controller is described in section 1.5. The Manipulator is equipped with maintenance-free AC motors, which have electromechanical brakes. The brakes lock the motors when the robot is inoperative for more than 1000 hours. The time can be configured by the user. The following figures show the various ways in which the different manipulators move and their component parts. Motor axis 5 Motor axis 6

Axis 3 Axis 4 Axis 5 Axis 6

Motor axis 4

Upper arm

Axis 2 Motor axis 1

Lower arm Motor axis 2

Motor axis 3 Axis 1

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

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Product Manual

Introduction

Motor unit axis 4 Motor unit axis 5 Motor unit axis 6 Axis 4 Axis 3

Upper arm

Axis 6 Axis 5 Motor unit and gearbox axis 1 Axis 2 Motor unit and gearbox axis 3 Axis 1 BaseFigure 5 The motion patterns of the IRB 2400.

Lower arm

Motor unit and gearbox axis 2

Axis 5 Axis 6

Upper arm

Axis 4

Motor axis 4 Motor axis 5 Motor axis 6 Axis 3

Lower arm Axis Motor axis Motor axis Axis 1 Motor axis Base

Figure 6 The motion patterns of the IRB 4400

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7

Introduction

Axis 3 Motor axis 4

Upper arm Axis4 Axis 5 Motor axis 6 Axis 6 Motor axis 5

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

Axis 1

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

Axis 3

Upper arm

Motor axis 6

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

Figure 8 The motion patterns of the IRB 640.

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Product Manual

Introduction

Motor 1(X)-axis

Motor 3(Z)-axis

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

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

Figure 9 The motion patterns of the IRB 840/A

Product Manual

9

Introduction. Axis 2 Axis 3 Y Axis 3 Axis 2

Upper arm (x3)

Motors encapsulated Axis 1

Base box Bars (x3)

Swivel XFigure 10 The motion patterns of the IRB 340.

Axis 4, telescopic shaft (option) Z

Motor axis 4 Motor axis 5 Motor axis 6

Axis 3 Axis 4 Upper arm Axis 5

Lower arm

Axis 2 Motor axis 1 Motor axis 3 Motor axis 2 Axis 1 BaseFigure 11 The motion patterns of the IRB 140.

Axis 6

10

Product Manual

Safety Contents1page

Safety 1.1 General............................................................................................ 1.1.1 Introduction .......................................................................... 1.2 Applicable Safety Standards ........................................................... 1.3 Fire-Extinguishing............................................................................ 1.4 Definitions of Safety Functions........................................................ 1.5 Safe Working Procedures ............................................................... 1.5.1 Normal operations ............................................................... 1.6 Programming, Testing and Servicing............................................... 1.7 Safety Functions.............................................................................. 1.7.1 The safety control chain of operation................................... 1.7.2 Emergency stops ................................................................. 1.7.3 Mode selection using the operating mode selector.............. 1.7.4 Programming and testing at reduced speed ........................ 1.7.5 Testing at full speed ............................................................. 1.7.6 Automatic operation ............................................................. 1.7.7 Enabling device ................................................................... 1.7.8 Hold-to-run control ............................................................... 1.7.9 General Mode Safeguarded Stop (GS) connection ............. 1.7.10 Automatic Mode Safeguarded Stop (AS) connection .......... 1.7.11 Limiting the working space................................................... 1.7.12 Supplementary functions ..................................................... 1.8 Safety Risks Related to End Effectors ............................................ 1.8.1 Gripper ................................................................................. 1.8.2 Tools/workpieces ................................................................. 1.8.3 Pneumatic/hydraulic systems .............................................. Risks during Operation Disturbances.............................................. Risks during Installation and Service .............................................. Dimensioning the safety fence ........................................................ Standards of interest when the robot is part of a cell ...................... Risks Associated with Live Electric Parts........................................ 1.13.1 Controller ............................................................................. 1.13.2 Manipulator .......................................................................... 1.13.3 Tools, material handling devices, etc. .................................. Emergency Release of Mechanical Arm ......................................... Limitation of Liability ........................................................................ Related Information .........................................................................

1 1 1 1 1 2 2 2 3 3 3 4 4 5 5 5 6 6 6 7 7 7 8 8 8 8 8 8 10 10 10 10 11 11 11 11 11i

1.9 1.10 1.11 1.12 1.13

1.14 1.15 1.16Product Manual

Safety

Contents

page

ii

Product Manual

Safety 11.1

SafetyGeneralThis 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. Userss Guide and Product Manual. The diskettes which contain the robots control programs must not be changed in any way because this could lead to the deactivation of safety functions, such as reduced speed. 1.1.1 Introduction Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.

1.2

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

1.3

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

Product Manual

1

Safety

1.4

Definitions of Safety FunctionsEmergency stop IEC 204-1, 10.7 A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous functions controlled by the robot. Enabling device ISO 11161, 3.4 A manually operated device which, when continuously activated in one position only, allows hazardous functions but does not initiate them. In any other position, hazardous functions can be stopped safely. Safety stop ISO 10218 (EN 775), 6.4.3 When a safety stop circuit is provided, each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit. It is necessary to reset the power to the machine actuators before any robot motion can be initiated. However, if only the power to the machine actuators is reset, this should not suffice to initiate any operation. Reduced speed ISO 10218 (EN 775), 3.2.17 A single, selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot. Interlock (for safeguarding) ISO 10218 (EN 775), 3.2.8 A function that interconnects a guard(s) or a device(s) and the robot controller and/or power system of the robot and its associated equipment. Hold-to-run control ISO 10218 (EN 775), 3.2.7 A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released.

1.5

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

1.5.1

Normal operations

Note! All normal operations in automatic mode must be executed from outside the safeguarded space.

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Product Manual

Safety

1.6

Programming, Testing and ServicingThe robot is extremely heavy and powerful, even at low speed. When entering into the robots 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 robots 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 robots 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. Check axis by axis in positions where the load of the manipulator arm and the gripper apply the maximum static torque on each axis. Do the brake function test by switching to motors Off when the axis has maximum load and check that the axis maintains its position. Do not change Transm gear ratio or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. - 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 Unit with him/her when entering through the safety gate to the robots working space so that no-one else can take over control of the robot without his/her knowledge.

1.71.7.1

Safety FunctionsThe 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 (LIM 1/ 2, ES1/2, GS 1/2, TPU En1/2, Man1/2, Auto1/2. See section Figure 1 on page 4). MOTORS ON mode means that drive power is supplied to the motors.

Product Manual

3

SafetyIf any contact in the safety chain of operation opens, the robot always reverts to MOTORS OFF mode. MOTORS OFF mode means that drive power is removed from the robots motors and the brakes are applied.K1 K2 Drive Unit M

K1

K2

Interlocking

EN RUN

&Man1 + LIM1 ES1 GS1 TPU En1 AS1 Auto1 LIM2 External contactors ES2 GS2

&Man2 + TPU En2 AS2 Auto2

Figure 1

Safety control chain of operation

The status of the switches is indicated by LEDs on top of the panel unit in the control cabinet and is also displayed on the Teach Pendant Unit (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 safety chains must never be bypassed, modified or changed in any other way. 1.7.2 Emergency stops An emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop buttons are located on the operators panel of the robot controller and on the Teach Pendant Unit. External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual - Installation and Commissioning). 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. 1.7.3 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.

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Product Manual

SafetyOne 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 robots safeguarded space. The robot must be operated using the Teach Pendant Unit 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 robots safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space. 1.7.4 Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows: 1. Set the operating mode selector to 500 V max. voltage 125 V nominal voltage

Figure 11 Examples of clamping circuits to suppress voltage transients.

2.4

Connection typesI/O, external emergency stops, safety stops, etc., can be supplied on screw connections or as industrial connectors.Designation X(T) XP XSTable 2

Screw terminal Pin (male) Sockets (female)Connection types

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Connecting Signals

Installation and Commissioning

2.5

ConnectionsDetailed information about connection locations and functions will be found in chapter 12, Circuit Diagram.

2.5.1

To screw terminal Panel unit and I/O units are provided with keyed screw terminals for cables with an area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one connection.

Note! The cable shield must be connected to the cabinet wall using EMC connecting cable glands. The shield must continue right up to the screw terminal. The installation should comply with the IP54 (NEMA 12) protective standard. Bend unused conductors backwards and attach them to the cable using a clasp, or similar. To prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0V) at both ends. 2.5.2 To connectors (option) Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652) can be found on the left-hand side or front of the cabinet (depending on the customer order) See Figure 12 and Figure 5.Operators panel External axes in separate cabinet Safety signals External conn. Device Net Mains conn.

I/O connections

External axes in Robot cabinet

Equipment Position switches connection to cabinet Application Interface

Manipulator cables

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

Product Manual S4Cplus

13

Installation and Commissioning

Connecting Signals

In each industrial connector there is space for four rows of 16 conductors with a maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when connecting the shield to the case. The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included). Bend unused conductors backwards and attach them to the cable using a clasp, or similar. To prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0V) at both ends. When contact crimping industrial connectors, the following applies: 1. Using a special crimp tool, crimp a pin or socket on to each non-insulated conductor. 2. The pin can then be snapped into the actual contact. 3. Push the pin into the connector until it locks. Also, see instructions from connector supplier. A special extractor tool must be used to remove pins or sockets from industrial connectors. When two conductors must be connected to the same pin or socket, both of them are crimped into the same pin or socket. A maximum of two conductors may be crimped into the same pin or socket.

2.6

Connection to screw terminalSockets with screwed connections for customer I/O, external safety circuits, customer sockets on the robot, external supply to electronics. See also note1.Signal identification Safeguarded stop Digital I/O Combi I/O Relay I/O RIO I/O COM21, COM31 CAN 1.1 (internal unit) CAN 1.2 (manipulator, I/O units) CAN 1.3 (external I/O units) CAN 2 (external I/O units) 24V supply (2A fuse) 115/230V AC supplyTable 3 Connections to screw terminal

Location Terminals Panel unit X1 - X4 I/O unit X1 - X4 I/O unit X1 - X4, X6 I/O unit X1 - X4 I/O unit X1, X2 Base Connector Unit X10, X9 Base Connector Unit X15 Base Connector Unit X6 Base Connector Unit X7 Base Connector Unit X8 XT31 XT21

Locations of socket terminals are shown in Figure 13. See also circuit diagram, View of control cabinet, for more details.1. The COM2 and COM3 ports was formerly referred to as SIO1 and SIO2

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Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

X6 (CAN 1.2) X7 (CAN 1.3)

X8 (CAN 2)

Base Connector UnitX10 (COM21) X9 (COM31) X15 (CAN1.1)

Cabinet view from above I/O Units (X4)

Computer system (COM11) XT 31 (24V I/O) Panel Unit Manipulator connections115/230 VAC X1-X4 Safety Signals

XT21

XP6

Connection to Position switches

XP5

XP58

XP8

Connection to Customer power Customer signalsFigure 13 Terminal locations. See also note1 1. The COM1, COM2 and COM3 ports was formerly referred to as Com2, SIO1 and SIO2

Product Manual S4Cplus

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Installation and Commissioning

Connecting Signals

2.7

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

LS

GS & AS

2:nd chain interlock

Drive unit

RUN EN1 EN2 Computer commands

M

ED

Manual mode

Automatic mode Operating mode selector AS = Automatic mode safeguarded space stop ED = TPU Enabling Device LS = Limit Switch ES = Emergency Stop GS = General mode safeguarded space stop

Figure 14 MOTORS ON /MOTORS OFF circuit.

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Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

2.7.124V1 X3:12 X4:12

Connection of safety chainsExt LIM1

K1 0V See 2.7.2

24 V

X1:11

12ES1

X3:10 + Opto GS1 8 11 + Opto AS1 9 -

isol.

TPU En1

&

EN RUN Interlocking

K1

isol.

K2

Auto1 External contactors 0V 24 V 0V X3:3 X4:3 4 4 CONT1 CONT2

Man1

Ext LIM2 X2:11 12 See 2.7.2 ES2+ Opto isol. +

K2 24V

X4:10 8 11 9X3:71 X4:7 0V -

Drive unit

GS2 TPU En2

&

M

Opto AS2 isol.

Auto2

Man2

Figure 15 Diagram showing the two-channel safety chain, see also note1.

Technical data per chain Limit switch: 300 mA 1V External contactors: 10 mA 4V GS/AS load at 24V 25 mA GS/AS closed 1 > 18V 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 signalsTable 4 Technical data per chain

load max. V drop load max. V drop

1. Supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. When external supply of GS and AS, X3/ X4:10,11 is connected to 24V and X3/X4:8,9 is connected to external 0V. X1-X4 connection tables, see section 2.8.

Product Manual S4Cplus

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Installation and Commissioning2.7.2 Connection of ES1/ES2 on panel unitExternal Internal 24V 0V 24V 0V External X1:4 X1:10X1:3

Connecting Signals

TPU

Cabinet X1:7

X1:9

E-stop relay X1:8

24V

X1:2 ES1 out X1:1 External Internal 0V 24V 0V 24V External X2:4 X2:10 X2:3 E-stop relay X2:9 X2:8 X2:6 X2:2 ES2 out X2:1Figure 16 Terminals for emergency circuits, see also note1.

TPU

Cabinet X2:7 0V

RUN CHAIN

Technical data ES1 and 2 out max. voltage ES1 and 2 out max. current 120VAC or 48VDC 120VAC: 4A 48VDC L/R: 50 mA 24VDC L/R: 2A 24VDC R load: 8A External supply of ES relays = Rated current per chain Max. potential relative to the cabinet earthing and other groups of signals Signal classTable 5 Technical data

min. 22V between terminals X1:9,8 and X2:9,8 respectively 40 mA 300V Control signals

1. Supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. When ext. supply, X1/X2:3 is connected to ext. 24V and X1/X2:8 is connected to ext. 0V (dotted lines).

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Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

2.7.3

Connection to Motor On/Off contactorsTechnical data K1 (Motor On/Off 1) K2 (Motor On/Off 2) Max. voltage Max. current Max. potential relative to the cabinet earthing and other groups of signals X3:2 1 X4:2 1Figure 17 Terminals for customer use.

48V DC 4A 300V

Signal class

Control signals

Table 6

Technical data

2.7.4

Connection to operating mode selectorTechnical data Max. voltage 48V DC 4A 300V

Auto1

MAN1

100% (Option) S1.1.x1

7 Max. current Max. potential rela6 tive to the cabinet earthing and other 5 groups of signals 4 Signal class 3 2

Control signals

Auto2

MAN2Figure 18 Terminals for customer use.

100% (Option)

1Table 7 Technical data

2.7.5

Connection to brake contactorTechnical data K3 (Brake) Max. voltage Max. current Max. potential relative to the cabinet earthing and other groups of signals Signal classFigure 19 Terminal for customer use. Table 8

48V DC 4A 300V

X4:5 6

Control signalsTechnical data

Product Manual S4Cplus

19

Installation and Commissioning

Connecting Signals

2.8

External customer connections on panel unit X1X4WARNING!REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT

EN

MS NS

ES1 ES2 GS1 GS2 AS1 AS2

Chain status LEDs

X1

1 2

3 4 5 6 7 8 9 10 11 12

1 2

3 4 5 6 7 8 9 10 11 12

X3

X2

1 2

3 4 5 6 7 8 9 10 11 12

1 2

3 4 5 6 7 8 9 10 11 12

X4

= jumperFigure 20 Customer connections: X1X4, located on the panel unit.

2.8.1

X1; 12-pole type Phoenix COMBICON connector See also note1.Signal1 ES1 out:A ES1 out:B ES1 top 24Vpanel Run Ch1 top ES1 internal Sep. ES1:A Sep. ES1:B ES1 bottom 0V Ext. LIM1:A Ext. LIM1:BTable 9

Terminal no: Comment 1 2 3 4 5 6 7 8 9 10 11 12 Emergency stop out chain 1 Emergency stop out chain 1 Top of emergency stop chain 1 +24V emergency stop chain 1 and run chain 1 Top of run chain 1 Internal signal from emergency stop relay chain 1 Separated emergency stop chain 1 Separated emergency stop chain 1 Bottom of emergency stop chain 1 0V emergency stop chain 1 External limit switch chain 1 External limit switch chain 1

Signal descriptions for X1

1. The signal names refer to the circuit diagram in Chapter 12.

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Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

2.8.2

X2, 12-pole type Phoenix COMBICON connector See also note1.Signal1 ES2 out:A ES2 out:B ES2 top 0V Run Ch2 top ES2 internal Sep. ES2:A Sep. ES2:B ES2 bottom 24Vpanel Ext. LIM2:A Ext. LIM2:BTable 10

Terminal no: Comment 1 2 3 4 5 6 7 8 9 10 11 12 Emergency stop out chain 2 Emergency stop out chain 2 Top of emergency stop chain 2 0V emergency stop chain 2 and run chain 2 Top of run chain 2 Internal signal from emergency stop relay chain 2 Separated emergency stop chain 2 Separated emergency stop chain 2 Bottom of emergency stop chain 2 24V emergency stop chain 2 External limit switch chain 2 External limit switch chain 2

Signal descriptions for X2

2.8.3

X3; 12-pole type Phoenix COMBICON connector.Signal1 Ext. MON 1:B 0V CONT1 Terminal no: Comment Motor contactor 1 Motor contactor 1 External contactor 1 0V External contactor 1 No connect No connect 0V to auto stop and general stop General stop minus chain 1 Auto stop minus chain 1 General stop plus chain 1 Auto stop plus chain 1 24V to auto stop and general stop 2 3 4 5 6 0V GS1 AS1 GS1 + AS1 + 24VpanelTable 11

Ext. MON 1:A 1

7 8 9 10 11 12

Signal descriptions for X3

1. The signal names refer to the circuit diagram in Chapter 12.

Product Manual S4Cplus

21

Installation and Commissioning2.8.4 X4; 12-pole type Phoenix COMBICON connector See also note1.Signal1 Ext. MON 2:A Ext. MON 2:B 24Vpanel CONT2 Terminal no: Comment 1 2 3 4 Motor contactor 2 Motor contactor 2 External contactor 2 24V External contactor 2 Contactor for external brake Contactor for external brake 0V to auto stop and general stop General stop minus chain 2 Auto stop minus chain 2 General stop plus chain 2 Auto stop plus chain 2 24V to auto stop and general stop

Connecting Signals

Ext. BRAKE A 5 Ext. BRAKE B 6 0V GS2 AS2 GS2 + AS2 + 24VpanelTable 12

7 8 9 10 11 12

Signal descriptions for X4

1. The signal names refer to the circuit diagram in Chapter 12.

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Connecting Signals

Installation and Commissioning

2.9

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

Panel unit

Relays with positive action

X4:4 CONT2 24 V X4:3 Ext MON 2 X4:2 K2 X4:1 X3:2 K1 Ext MON 1 X3:1 0 V X3:3 CONT1 X3:4

0V

24 V

Robot 1

Robot 2

(only one channel displayed)

External supply ES out External supply Cell ES

AS GS ES out

AS GS

Safety relay

To other equipment Safety gate

Figure 21 Diagram for using external safety relays.

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Connecting Signals

2.10

Safeguarded space stop signalsAccording to the safety standard ISO/DIS 11161 Industrial automation systems safety of integrated manufacturing systems - Basic requirements, there are two categories of safety stops, category 0 and category 1. A safety analysis will show if category 0 or 1 is applicable, see Table 13 below.Category 0 The category 0 stop is to be used when the power supply to the motors must be switched off immediately, such as when a light curtain, used to protect against entry into the work cell, is passed. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop.Table 13 Description of safety categories

Category 1 Category 1 is preferred if it is acceptable, such as when gates are used to protect against entry into the work cell. This controlled motion stop takes place within the programmed path, which makes restarting easier.

2.10.1 Delayed safeguarded space stop All the robots 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 Users Guide - System Parameters, Topic: Controller.

2.11

Available voltage

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

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2.11.2 115/230 VAC supply The robot has an AC supply available for external and internal use. This voltage is used in the robot for supplying optional service outlets. The AC supply is not galvanically separated from the rest of the controller voltages. Technical data Voltage 115 or 230V Permitted customer load Max. 500VA Fuse size 3.15A (230V), 6.3A (115V) AC supply is available for customer connections at XT 21 see Figure 13. XT.21.1-5 230V (3.15A) XT.21.6-8 115V (6.3A) XT.21.9-13N (connected to cabinet structure)

2.12

External 24V supplyAn 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 24V supply An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I/O units or on the panel unit. The neutral wire in the external supply must be connected in such a way as to prevent the maximum permitted potential difference in the chassis earth being exceeded. For example, a neutral wire can be connected to the chassis earth of the controller, or some other common earthing point. Technical data: Potential difference to chassis earth: Permitted supply voltage:

Max. 60V continuous Max. 500V for 1 minute I/O units 1935V including ripple panel unit 20.630V including ripple

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

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Installation and Commissioning

Connecting Signals

2.13

Connection and address keying of the CAN-bus

2.13.1 CAN 1.1 - 1.3. Control cabinetBase connector unit I/O X15 CAN1.1 (Internal I/O) I/O I/O No termination of the last unit

CAN bus

X6 CAN1.2 X7 CAN1.3

See Figure 22.

I/O

I/O

I/O

I/O

I/O

I/O Termination of last unit

X15, X6, X7

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

1. 2. 3. 4. 5.

120 ohm, 1% 0.25 W Metal film

Figure 22 Example of connection of the CAN-bus

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- CAN 1.1 is used for internal I/O unit mounted inside the cabinet. No terminating resistor is to be mounted on CAN 1.1 regardless of whether there are any I/O units mounted or not. CAN 1.1 is connected to socket X15 on the Base connector unit (see 2.6). - If CAN 1.2 is unused there should be a terminating resistor mounted in the X6 socket (exceptional case see below). - If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.2 chain. - If CAN 1.3 is unused there should be a terminating resistor mounted in the X7 socket (exceptional case see below). - If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit on the CAN 1.3 chain. Note! If CAN 1.2, for example, is not connected in the end of any CAN chain but somewhere between the end points of the chain, then no terminating resistor should be mounted in CAN 1.3. This is in accordance with the basic rule, i.e. the CAN chain should be terminated in both end points. 2.13.2 CAN 2Controller Base connector unit

See Figure 24I/O I/O I/O

X8 CAN 2

X8

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

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

1. 2. 3. 4. 5.

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

Figure 23 CAN 2

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

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Installation and Commissioning

Connecting Signals

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

Figure 24 CAN connections on base connector unit.

2.13.3 DeviceNet ConnectorX5 Input and ID12

Signal name V- 0V CAN_L DRAIN CAN_H V+ GND MAC ID 0 MAC ID 1

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)

1

MAC ID 2 MAC ID 3 MAC ID 4 MAC ID 5

Table 14

2.13.4 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 25. When all terminals are unconnected the highest address is obtained, i.e. 63. When all are connected to 0V, the address is 0 (which will cause an error since address 0 is used by the Panel unit). To avoid interference with other internal addresses, do not use addresses 09.

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

Example: To obtain address 10: cut off address pins 2 and 8, see figure. To obtain address 25: cut off address pins 1, 8 and 16.Figure 25 Examples of address keying.

1

2

4

8

16

32

2.14

Distributed I/O units

2.14.1 General Up to 201 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 Users Guide, section System Parameters, Topic: I/O Signals. 2.14.2 Sensors Sensors are connected to one optional digital unit. Technical data See Product Specification for controller S4Cplus.

1. Some ProcessWare reduces the number due to the use of SIM boards.

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29

Installation and CommissioningThe following sensors can be connected:Sensor type Digital one bit sensors Digital two bit sensors Signal level High Low High No signal Low Error statusTable 15 Sensors

Connecting Signals

1 0 01 00 10 11 (stop program running)

2.14.3 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 24V I/O supply or from a separate supply. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For Circuit diagram, see Chapter 12. Connection table Customer connections X1X4Status LEDs OUT IN X1 1 10 X2 1 X4 10 1 10 10 MS NS OUT9 10 11 12 13 14 15 16

1

2

3

4

5

6

7

8

IN

X3

1

12

1 X5

CAN-connection, see 2.13

Figure 26 Digital I/O unit DSQC 328

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Connector X1, X2, see also note1X1 Unit function Opto. isol. Signal name Out ch 1 Out ch 2 Out ch 3 Out ch 4 Out ch 5 Out ch 6 Out ch 7 Out ch 8 0V for out 18 24V for out 18Table 16 Connection table, X1 and X2

X2 Customer connection Signal name Out ch 9 Out ch 10 Out ch 11 Out ch 12 Out ch 13 Out ch 14 Out ch 15 Out ch 160V

Pin 1 2 3 4 5 6 7 8 9 101

Pin 1 2 3 4 5 6 7 8 9 101

0V for out 916 24V for out 916

24V

Connector X3, X4X3 Unit function Opto. isol. Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 18 Not usedTable 17 Connection table, X3 and X4

X4 Customer connection Signal name24V

Pin 1 2 3 4 5 6 7 8 9 10

Pin 1 2 3 4 5 6 7 8 9 10

In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16

0V

0V for in 916 Not used

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

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

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Installation and Commissioning2.14.4 AD Combi I/O DSQC 327 (optional)

Connecting Signals

The combi I/O unit has 16 digital inputs divided into groups of 8, and 16 digital outputs divided into two groups of 8. All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply. The two analog outputs belong to a common group which is galvanically isolated from the electronics of the controller. The supply to the two analog outputs is generated from 24 V_CAN (with galvanically isolated DC/AC converter). Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For Circuit diagram, see chapter 12. Connection Table Customer connections X1X4, X6.Status LEDs OUT IN X1 1 10 X2 1 X4 1 10 10 MS NS OUT9 10 11 12 13 14 15 16

1

2

3

4

5

6

7

8

IN

X6 1 6

X3

1

10

12

1 X5

CAN-connection, see 2.13

Figure 27 AD Combi I/O DSQC 327

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Connector X1, X2, see also note1X1 Unit function Opto. isol. Signal name Out ch 1 Out ch 2 Out ch 3 Out ch 4 Out ch 5 Out ch 6 Out ch 7 Out ch 8 0V for out 18 24V for out 18Table 18 Connection table, X1 and X2

X2 Customer connection Signal name Out ch 9 Out ch 10 Out ch 11 Out ch 12 Out ch 13 Out ch 14 Out ch 15 Out ch 160V

Pin 1 2 3 4 5 6 7 8 9 101

Pin 1 2 3 4 5 6 7 8 9 101

0V for out 916 24V for out 916

24V

Connector X3, X4X3 Unit function Opto. isol. Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 18 Not usedTable 19 Connection table, X3 and X4

X4 Customer connection Signal name24V

Pin 1 2 3 4 5 6 7 8 9 10

Pin 1 2 3 4 5 6 7 8 9 10

In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16

0V

0V for in 916 Not used

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

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Installation and CommissioningConnector X6X6 Signal name AN_ICH1 AN_ICH2 0V 0VA AN_OCH1 AN_OCH2Table 20

Connecting Signals

Pin 1 2 3 4 5 6

Explanation For test purpose only For test purpose only 0V for In 1-2 0V for Out 1-2 Out ch 1 Out ch 2

Connection table, X6

Note! The input current is 5.5 mA (at 24V) on the digital inputs. A capacitor connected to ground, to prevent disturbances, causes a short rush of current when setting the input. When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ) may be used. 2.14.5 Analog I/O DSQC 355 (optional) The analog I/O unit provides the following connections: 4 analog inputs, -10/+10V, which may be used for analog sensors etc. 4 analog outputs, 3 for -10/+10V and 1 for 4-20mA, for control of analog functions such as controlling gluing equipment etc. 24V to supply external equipment with return signals to DSQC 355. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For Circuit diagram, see chapter 12.

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Connection table Customer connections: X1, X3, X5X8 X8-Analog inputs X7-Analog outputs

Bus status LEDs

X8 S2 S3 X2 X5 X3

X7

Analog I/O

DSQC 355

ABB flexible Automation

X5-DeviceNet input and ID connectorFigure 28 Analog I/O unit

Not to be used

Connector X5 DeviceNet connectors. See section 2.13.3.

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Installation and CommissioningConnector X7 - Analog outputs.X7 Signal name ANOUT_ ANOUT_ ANOUT_ ANOUT_ 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 Not to be used Not to be used GND GND GND GND GND GNDTable 21

Connecting Signals

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24Connection table, X7

Description Analog output 1, -10/+10 Analog output 2, -10/+10 Analog output 3, -10/+10 Analog output 4, 4-20mA

1

13

12

24

Analog output 1, 0V Analog output 2, 0V Analog output 3, 0V Analog output 4, 0V

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

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Installation and Commissioning

Connector X8 - Analog inputsX8 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 GNDTable 22

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 32Connection table, X8

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

1

17

16

32

+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

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

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Installation and Commissioning2.14.6 Encoder interface unit DSQC 354

Connecting Signals

The encoder interface unit provides connections for 1 encoder and 1 digital input. The encoder is used for installation on a conveyor to enable robot programs to synchronise to the motion (position) of the conveyor. The digital input is used for external start signal/ conveyor synchronisation point. Further information User Reference Description Conveyor Tracking. For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12. Connection table Customer terminals:X20 Conveyor connection

X20Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A

X5

X3

X5-DeviceNet input and ID connector

X3 Not to be used

Figure 29 Encoder interface unit DSQC 354

Connector X5 DeviceNet connectors. See section 2.13.3.

38

DSQC 354

Encoder

CAN Rx CAN Tx MS NS POWER

ABB Flexible Automation

Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

Encoder unit24V I/O or external supply 0V 24V DC 0V Encoder A B 24V DC Sync switch 0V

10-16 not to be used

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

Opto Opto

Opto

Opto Opto

Opto

Galvanic insulation

Figure 30 Encoder connections.

The wiring diagram in Figure 30 shows how to connect the encoder and start signal switch to the encoder unit. As can be seen from the illustration, the encoder is supplied with 24 VDC and 0V. The encoder output 2 channels, and the on-board computer, use quadrature decoding (QDEC) to compute position and direction.

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Installation and CommissioningConnector X20 - Encoder and digital input connectionsX20 Input and ID Signal name 24VDC 0V ENC 1 ENC ENC_A ENC_B DIGIN DIGIN DIGIN Not to be used Not to be used Not to be used 16 Not to be used Not to be used Not to be used Not to be usedTable 23 Connection table, X20

Connecting Signals

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

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

2.14.7 Relay I/O DSQC 332 16 output relays each with a single Normal Open contact, independent of each other. 16 digital 24V inputs divided into groups of 8. The groups are galvanically isolated. Power supplies to customer switches can be taken either from the cabinet 24 V I/O or from a separate supply. Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12.

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Installation and Commissioning

Connection table Customer connections: X1 - X4Status LEDs1 2 3 4 5 6 7 8

OUT IN

MS NS

OUT9 10 11 12 13 14 15 16

IN X2

X1 1 X3 1 16 1 16 16 1 16

X4

12

1 X5

CAN-connection, see 2.13

Figure 31 Relay I/O unit DSQC 332

Connector X1, X2X1 Unit function Signal name Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8bTable 24 Connection table, X1 and X2

X2 Customer connection Signal namesupply

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

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

Out ch 9a Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b

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Installation and CommissioningConnector X3, X4X3 Unit function Opto. isol. Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 18 Not used Not used Not used Not used Not used Not used Not usedTable 25 Connection table, X3 and X4

Connecting Signals

X4 Customer connection Signal name24V

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

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

In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16

0V

0V for in 916 Not used Not used Not used Not used Not used Not used Not used

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

2.15

Digital 120 VAC I/O DSQC 320Technical data See Product Specification for controller S4Cplus. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12.

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Connection Table Customer connections: X1X4Status LEDs OUT IN X1 1 X3 1 16 1 16 16 1 16 X4 MS NS OUT9 10 11 12 13 14 15 16

1

2

3

4

5

6

7

8

IN X2

12

1 X5

CAN connection, see 2.13

Connector X1, X2X1 Unit function Opto isol. Signal name Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8bTable 26 Connection table, X1 and X2

X2 Customer connection Signal nameAC supply

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

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

Out ch 9a Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b

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Installation and CommissioningConnector X3, X4X3 Unit function Opto isol. Signal name Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8bTable 27 Connection table, X3 and X4

Connecting Signals

X4 Customer connection Signal nameAC N

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

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

Out ch 9a Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b

2.16

Gateway (Field bus) units

2.16.1 RIO (Remote Input Output), remote I/O for Allen-Bradley PLC DSQC 350 The RIO-unit can be programmed for 32, 64, 96, or 128 digital inputs and outputs. The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor cable. Technical data See Allen-Bradley RIO specification. Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12.

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Connection Table Customer terminals: X8 and X9

X5 Device net input and ID connector

X5 X9 RIO out

POWER NS MS CAN Tx CAN Rx NAC STATUS

X8 X3 Not to be used DSQC 350ABB Flexible Automation

RIO in

Figure 32 RIO-unit

Connector X5 DeviceNet connectors. See section 2.13.3. Connector X8, X9X8 Signal name LINE1 (blue) LINE2 (clear) shield cabinet groundTable 28

X2 Signal name Remote I/O in blue clear shield cabinet ground Pin 1 2 3 4 Remote I/O out

Pin 1 2 3 4

Connection table, X1 and X2

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

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Installation and CommissioningRIO communication conceptAllen Bradley control system

Connecting Signals

Robot 1 - 128 in / 128 out Quarter 1 Quarter 2 Quarter 3 Quarter 4 Rack ID 12 (example) Rack size 4 Starting quarter 1 128 in / 128 out

Robot 2 - 64 in / 64 out Quarter 1 Quarter 2 Rack ID 13 (example) Rack size 2 Starting quarter 1 Robot 3 - 64 in / 64 out Quarter 3 Quarter 4 Rack ID 13 (example) Rack size 2 Starting quarter 3 64 in / 64 out 64 in / 64 out

Other systems Quarter 1 Quarter 2 Quarter 3 Quarter 4

Figure 33 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 the I/O system in the robot. For example, the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment via general I/O addresses and the Allen Bradley system only reads the outputs as status signals. 2.16.2 Interbus-S, slave DSQC 351 The unit can be operated as a slave for a Interbus-S system. The Interbus-S slave must have a external power feed so that the Interbus-S net would not shut down if a robot cell is turned off. The 24V power feed must come from outside the control cabinet and be connected to the 2 pin Phoenix connector located on the Interbus-S cards front panel marked 24V. Technical data See Interbus-S specification.46 Product Manual S4Cplus

Connecting Signals

Installation and Commissioning

Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12. Unit ID to be entered in the Interbus-S master is 3. The length code depends on the selected data. Width between 1 and 4. Customer terminals: see figure below regarding locations.X20 Interbus-S in X21 Interbus-S out

X20RC BA RBDA POWER

X21

X5

X3

X5-DeviceNet input and ID connector

X3 Interbus-S supply

Figure 34 Interbus-S, DSQC 351

Connector X5 DeviceNet connectors. See section 2.13.3. Communication concept128 in/128 outMaster PLC Robot 1 .3 Word 1.3 IN OUT *1Figure 35 Outline diagram.

DSQC 351

Interbus-S

CAN Rx CAN Tx MS NS POWER

ABB Flexible Automation

64 in/64 outRobot 3 2 Word 8.11 .11 IN *1 OUT

Robot 1 2 .7 Word 4.7 IN OUT

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.

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Installation and Commissioning

Connecting Signals

Note! That there is a link between pins 5 and 9 in the plug on the interconnection cable which is connected to the OUT connector for each unit. The link is used to inform the Interbus-S unit that more units are located further out in the chain. (The last unit in the chain does not have a cable connected and therefore no link). Connector X20X20 Interbus-S IN Signal name TPDO11 5

Pin 1 2 3 4 5 6 7 8 9

Description 24VDC supply 0V Communication line TPDO1 Communication line TPDI1 Ground connection Not connected Not connected Communication line TPDO1-N Communication line TPDI1-N

TPDI16 9

GND NC NC TPDO1-N TPDI1-N NC NC

Table 29

Connection table, X20

Connector X21X21 Interbus-S OUT Signal name 0 V DC1 5

Pin 1 2 3 4 5 6 7 8 9

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

NC6 9

GND NC + 24 V DC TPDO2-N TPDI2-N NC RBST

Table 30

Connection table, X21

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Installation and Commissioning

Connector X3X3 Interbus-S supply5

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

Pin 1 2 3 4 5

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

1

Table 31

Connection table, X20

Note! An external supply is recommended to prevent loss of fieldbus at IRB power off. 2.16.3 Profibus-DP, slave, DSQC352 The unit can be operated as a slave for a Profibus-DP system. The Profibus does not need any external power feed. All the robot cells are connected to the trunk cable through a special D-sub connector which works as a very short drop cable. Because of this the profibus will work correctly even if a robot cell is turned off. Technical data See Profibus-DP specification, DIN E 19245 part 3. Further information For setup parameters, see Users Guide - System Parameters, Topic: IO Signals. For circuit diagram, see chapter 12. Connection Table Customer connections.X20 Profibus connection

X20

PROFIBUS ACTIVE

X5 - DeviceNet connector

X5

X3

DSQC 352

Profibus

NS MS CAN Tx CAN Rx POWER

ABB Flexible Automation

X3 - Power connector

Figure 36 DSQC352, location of connectors

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Installation and CommissioningConnector X5 DeviceNet connectors. See section 2.13.3. Communication concept256 in/256 out Master PLC Robot 1 .3 Word 1:8 Robot 1 .7 Word 9:16

Connecting Signals

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

Figure 37 Profibus-DP communication concept

The Profibus-DP system can communicate with a number of external devices. The actual number depends on the number of process words occupied of each unit. The robot can be equipped with one or two DSQC352. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs. For application data, refer to Profibus-DP, International Standard, DIN 19245 Part 3. Note! The Profibus cable must be terminated in both ends. Connector X20X20 Profibus-DP Signal name Shield1 5

Pin 1 2 3 4 5 6 7 8 9

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

NC6 9

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

Table 32

Connection table, X20

Connector X3X3 Profibus-DP supply5

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

Pin 1 2 3 4 5

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

1

Table 33

Connection table, X20

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2.17

Communication

2.17.1 Serial links The robot has three serial channels, which can be used by the customer to communicate with printers, terminals, computers, and other equipment (see Figure 38). The serial channels are: For permanent use. - COM21 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission speed 300 - 38 400 b/s. - COM31 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 - 38 400 b/s. - COM12 (computer system) - RS 232 115 kbps. For temporary use. - MC/CONSOLE3 - RS 232 115 kb/s Further information - For setup parameters, see Users Guide - System Parameters, Topic: Controller. - For circuit diagram, see chapter 12. - Location in the cabinet see Figure 13. Technical data See Product Specification for controller S4Cplus. Separate documentation is included when the option RAP Serial link is ordered. Connection table

External computer

Figure 38 Serial channels, SLIP, outline diagram.

Customer terminals, on base connector board: X10 (COM21) and X9 (COM31), see section 2.6.1. The COM2 and COM3 ports was formerly referred to as SIO1 and SIO2 2. The COM1 port was formerly referred to as Com2. 3. The MC/CONSOLE port was formerly referred to as Com1.

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Installation and CommissioningDSQC 504 (D-sub connectors) Seem also note1COM21 Signala RXD 5 6 9 TXD DTR 1 0V DSR RTS N CTS N X10 Pin 1 2 3 4 5 6 7 8 9Table 34 Connection table, X3 and X4

Connecting Signals

COM31 Signala TXD TXD N 5 9 6 RXD RXD N 1 0V DATA DATA N DCLK DCLK N

X9 Socket 1 2 3 4 5 6 7 8 9

a. 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.

COM 12 RS232 signal port. Technical data See Product Specification - S4Cplus.Signal DCD DSR RX RTS TX CTS DTR RI GND NCTable 35

Pin 1 6 2 7 3 8 4 9 5 10

Description Data Carrier Detect Data Set Ready Receive Data Request to Send Transmit Data Clear to Send Data Terminal Ready Ring indicator Signal ground Not Connected

Signals from COM 12 (RS232)

1. The COM2 and COM3 ports was formerly referred to as SIO1 and SIO2 2. The COM1 port was formerly referred to as Com2.

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External computer

Figure 39 Connection to COM1 connector on computer chassis

MC/CONSOLE1 RS232 signal port for temporary use, e.g. connection of Laptop/PC. Technical data See Product Specification - S4Cplus.Signal RX TX GNDTable 36

Pin 2 3 5

Description Receive Data Transmit Data Signal ground

Signals from MC/CONSOLE1 (RS232)

External computer

Figure 40 Connection behind service hatch.

1. The MC/CONSOLE port was formerly referred to as Com 1

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Installation and Commissioning2.17.2 Ethernet communication There are two Ethernet channels available.

Connecting Signals

1. LAN (Main computer) Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no termination for a cable shield. The cable shield must be grounded at the cabinet wall with a cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see figure Figure 41.External Computer Controller Robot 1 Controller Robot 2 etc.

Ethernet HUBFigure 41 Ethernet TCP/IP, Outline diagram.

1 8

X1 Signal name TX+ TXRX+ NC NC RXNC NCTable 37

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

X1LAN

PWR

Signals from X1 LAN (Ethernet) port (see Figure 42)HDD

STATUS

X2

Figure 42 Main Computer Card Bracket

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2. Service (I/O computer) Used for connection to a Laptop via outlet on cabinet front (behind service hatch) on the controller see Figure 43.

Ethernet

Figure 43 Connection to Laptop via service outlet.

Further information For setup parameters, see Users Guide - System Parameters, Topic: Controller. For circuit diagram, see chapter 12. Separate documentation is included when the option Ethernet services is ordered.

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2.18

External operators panelAll 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

196

Required depth 200 mm193

223

180 224 240

70

62

96 Holes for flange

140 184

External panel enclosure (Option)

200 Holes for operators panel

100%

Teach pendant connection

Holes for teach pendant holder 90

Connection to the controller

5 (x2)

155

Figure 44 Required preparation of external panel enclosure.

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Installation and Commisioning 33.1

Controller softwareIntroductionThe robot controller includes a working memory (RAM) and a mass storage memory. The mass storage memory is a semiconductor memory (flash disk), but works like a hard disk. When the robot controller is up and running, the operating system and all programs are executed in the working memory. However, all code for the operating system and all relevant data, are always stored in the storage memory. This means that, e.g. when the power is broken, all system data is stored in the storage memory, and when repowering the system, all the code and data is restored from to the working memory and the system is restarted. In this case the system status and all data are restored to exactly the same values as before the power break. This is normally referred to as a warm start. The first time a robot controller shall be started, a so called cold start must be done. This requires that the code for the operating system is already installed in the storage memory (see below), and if so it is loaded into the working memory and started. In this case the system will enter a defined start-up status. Note! Both warm and cold starts can also be done as a manual restart. For more information on Controller Start-up and Set-up, see chapter 4. If the robot controller is ordered with the software installed on delivery, the controller software and settings are already stored in the storage memory and the system is ready to use. If the robot controller is ordered and delivered without software or if you want to reconfigure your system, the RobInstall tool must be used to install the controller software. The RobInstall tool is included on the RobotWare CD-ROM (see section 3.1.1). The RobInstall tool can be used both for creation of the controller software and for down loading it to the controller system. When downloading, the controller software can be transferred to the controller storage memory in three ways (see Figure 45): - using floppy disks, - using Ethernet connected direct to the IO computer (IOC) service outlet on the front of the controller cubicle, - using Ethernet connected via a local area network (LAN) to the main computer (MC).

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RobotWare CD-ROM To install RobInstall and System Pack on PC Floppy disks

IOC-Ethernet (Service) with delivered boot cable UTP-X

Connected to IOC MC-Ethernet (LAN) Network in workshop

Figure 45 RobotWare CD-ROM installation on PC and Controller Software installation to the robot controller.

The transfer and installation of the controller software to the controller storage memory via Ethernet or floppy disks is executed by a basic program named Boot Image. This basic program must always be in the storage memory. At start-up of the controller, without any controller software installed, Boot Image will start and ask the operator how the controller software should be installed. If the controller software is already installed and a warm start is done, Boot Image is not used. The installed controller software can be deleted by cold start and then the Boot Image will be active again. 3.1.1 The RobotWare CD-ROM

Note! The CD contains all the System software and should therefore be treated and stored carefully. Contents of the RobotWare CD-ROM: RobInstall: A PC tool used to create and install the controller operating system in the robot control system. Documentation: On-line documentation for the RobInstall application and the Controller Operating System Package. Controller OS Package (RobotWare: Controller Operating System Package for S4Cplus. This package includes all the software needed to create the controller operating system with any ordered options. Please note that it is possible to install different releases with different versions of the same system package (see section 6.1). Test Signal Viewer: A tool (created in LabView) for viewing MotionTest Signals (oscilloscope function) and also for logging these signals.

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3.1.2

Installation of the RobotWare on the PC Insert the CD in your reader. The Install Shield will automatically start and guide you through the install process (if it does not start, double-click the CD icon on your PC). When the setup type window is presented, it is recommended to select the Custom button. Then Next button will open the Select Components window, where normally all the four options, RobInstall, Documentation, Controller OS Package and Test Signal Viewer should be marked as selected.

3.1.3

Additional content on the RobotWare CD-ROM FTP Client: On the CD is also included a so called FTP client named Voyager. Please note that this is not an ABB product but a shareware program, which means that it can be installed and used for a limited time, but that it has to be registered for permanent use. Registering means that a certain fee must be paid to the vendor.

Note! ABB takes no responsibility for the installation or use of Voyager FTP client. Please refer the vendor of this product for all questions regarding the Voyager application. The FTP client is used to transport files manually between the PC and the robot controller storage memory. These actions are carried out in the same way as in a file manager or in Windows Explorer. To install the FTP Client: In the Explorer, select and open the directory ftp on the CD. Double-click the file ftpvsetup.exe. The Install Shield for the FTP client will start and guide you through the installation. Please read the Readme file for information about license regulations. 3.1.4 The manipulator parameter disk: The manipulator parameter disk contains the calibration offsets, which are needed to guarantee the accuracy of the robot. They are included in a so called system parameter file, calib.cfg, which can be included when a new robot controller operating system is created with the RobInstall tool (see section 3.2). See also section 5.2 for information on how to install the manipulator parameters in the controller. Note! The disk is attached to the manipulator on delivery. If no manipulator parameter disk is available, the calibration offsets and instructions on how to load the parameters manually, can be read from a label attached to the manipulator.

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3.2

Installing new Robot Controller Software with RobInstallSince most systems have the operating system installed already on delivery, the RobotWare CD-ROM is normally not needed. However it should be used when: - creating a new controller operating system, - changing the current operating system configuration, e.g. concerning included options. In the following text the following notations are used: System pack. This is the RobotWare Controller Operating System Package for S4Cplus, including all options, even if they are not ordered and activated. Key. This is a text string, or a special file with the text string, which is used to define and open both the BaseWare and all ordered RobotWare options. System. This is a complete controller software, i.e. controller operating system, based on the system pack and the key. It can also include any user files to be added to the home directory on the controller storage memory.

3.2.1

How to use RobInstall Robinstall is used to create and install the controller software in the S4Cplus robot controller. With RobInstall, you can: - create a new system, - update an existing system, - down load a system to the controller using Ethernet connection, - create Boot Disks to transfer the system to the Controller. If you have not already installed RobInstall, please install it according to the instructions in section 3.1.2. 1. Click the start button on your PC and select programs/ABB Robotics/RobInstall/RobInstall. 2. The RobInstall start window will open.

Figure 46 Start Window

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3.3

Create a new Robot Controller SystemStart RobInstall as described in section 3.2.1.

3.3.1

Setting up the system 1. Choose system New to create a new Robot Controller

Figure 47 Create a new system

2. Enter a name for the new controller system. Select a saving location or use the default directory, normally Program Files\ABB Robotics\system (see Figure 48, position 1). 3. Enter the RobotWare key or add from file. If added from file, files with the extension .kxt should be used (see Figure 48, position 2).

1

2

Figure 48 Create New System dialog box

4. Press OK. The configured system will be displayed in the next window (see Figure 49) 5. If no external options or parameters are to be added or changed, press Finish to create the new controller system. Otherwise press Next to continue to Additional Keys (see section 3.3.2).Figure 49 Display of configured system

3.3.2

Add or remove external options 1. To add or remove external options, press Next in the screen shown in Figure 49 or click on Additional Keys in the menu to the left. 2. Enter the key string for the selected option and press Add Key to list, or press Add key from file to select a key string file. 3. To remove additional keys, select the key in the Figure 50 Add external option keys Included Additional Keys list and press Remove Key. 4. Press Finish to create the controller system or press Next to continue to Parameter Data (see section 3.3.3).

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Installation and Commisioning3.3.3 Add or remove additional system parameters

Controller software

1. To add or remove additional parameters, press 1 Next in the screen shown in Figure 50 or click on Parameter Data in the menu to the left. 2 2. Press Add to load manipulator calibration data (see Figure 51, position 1). This is the calib.cfg file which is delivered on the Manipulator Parameter disk (see section 3.1.4). Figure 51 Load Parameter Data 3. To remove manipulator calibration data, press Remove. 4. Press Add to load additional system parameters, see pos. 2. All system parameter files added here will be automatically loaded together with the system, when the controller is restarted with the new system. 5. To remove additional parameters, select the parameter in the Loaded Additional Parameters list and press Remove. 6. Press Finish to create the controller system or press Next to continue to Options (see section 3.3.4). 3.3.4 Change options or system pack revision 1. To change the option configuration, press Next 1 in the screen shown in Figure 51 or click on Options in the menu to the left. 2. To change the Teach Pendant Unit language, robot type, or software options, press Options (see 2 Figure 52, position 1). 3. Normally the latest release or revision of all system Figure 52 Change Option packages and option packages stored in the media Configuration pool will be used. If an earlier revision should be used, uncheck the check mark and press Rev. Select (see Figure 52, position 2). In the new window select the system package to use and press OK. 4. If you want the system to start up in query mode, put a mark in the query mode selection square. For further details of the query mode, see section 4.8. 5. Press Finish to create the controller system or press Next to view the current configuration.

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3.4

Update the Robot Controller image1. To update an existing controller system, press Update, see Figure 53.

Figure 53 Update image

2. Select a system in the system list and press OK, see figure Figure 54. Please note that a pop up menu can be shown by clicking right mouse button. With this menu Copy, Rename or Delete can be selected for the marked system. 3. The window displaying the current configuration of the system will be shown. Follow the instructions in section 3.3.2, 3.3.3 and 3.3.4 to modify the system.Figure 54 Select system

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3.53.5.1

Transfer Robot Controller System using Ethernet connectionSet up before down loading a Robot Controller System Before a system can be down loaded to a robot controller using the RobInstall tool some preparations and set up must be done. If using direct connection between PC and IOC service outlet on controller: 1. Connect patch-cable between the Ethernet connection on the front of the controller and the corresponding connection on the PC/Laptop. 2. Make sure that the Network protocol is set for TCP/IP properties. 3. Change the TCP/IP Properties in accordance with the following table (Table 38) and figure (Figure 55):

IP Address: Subnet Mask: Default Gateway:Table 38

192.168.125.82 255.255.255.240 192.168.125.81Figure 55 The TCP/IP properties dialog box in Microsoft Windows

The TCP/IP properties for direct connection between PC and IOC service outlet

If using Network Intranet connection with fixed IP addresses: 1. Make sure that the Network protocol is set for TCP/IP properties. 2. Change the TCP/IP Properties in accordance with the values to be used for IP address, Subnet mask and Gateway. 3. Perform a X-START (see section 4.7.3) or C-START (see section 4.7.5) on the S4Cplus controller. 4. Configure the IP address to be used for the robot controller from the TPU. If using Network Intranet connection with DHCP (Dynamic Host Configuration Protocol) 1. Read Ethernet MAC-id on the Teach Pendant Unit (see section 4.5.1).

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3.5.2

Down load Robot Controller System Before starting to down load, make sure there are at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section 6.3.1.

Note! Before down loading, make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see section 4.2). 1. To down load a controller system, press load (see Figure 56). Down

Figure 56 Down load Robot Controller images

2. Select a target system (see Figure 57, position 1). If a direct connection is used with the patch cable 1 between the PC and the controller front, then just select the default IP address (192.168.125.1) and Direct option. 2 In other cases, write the correct IP address for the robot controller and select Hostname or IP-address. Figure 57 Select Target System RobInstall will store already used IP addresses, which can later be selected with the down arrow. 3. Fill in your username and password if it is required by the robot controller (see Figure 57, position 2). 4. Test the connection by pressing Test Connection and press OK if a connection is established. 5. Select a system in the list on the left and press OK (see Figure 58). Please note that it is possible to select another system pool than the shown one (in such case be sure to select the system pool directory, not the system itself on the lower level). 6. RobInstall will now create a system file and down load it to the controller. 7. After down loading it is possible to restart the controller with the new down loaded controller system. Otherwise, the controller can be restarted from the Teach Pendant Unit (see section 4.3). Figure 58 Select System

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3.63.6.1

Transfer Robot Controller System using floppy disksSet up before Robot Controller System transfer Make sure that the optional floppy disk drive is installed in the robot controller. Before starting to transfer the system from the disks to the controller, make sure there are at least 25 Mb free disk space on the controller mass storage memory. For information on how to perform a manual storage capacity check, see section 6.3.1.

3.6.2

Create Boot Diskettes from RobInstall 1. Press Create Boot Disk (see Figure 59).

Figure 59 Create Boot Diskettes

2. Select a system in the list on the left and press OK (see Figure 60). 3. RobInstall will now create an image file and estimate the number of disks needed. 4. Insert a formatted 1.44 Mb diskette into the disk drive. 5. Press Continue to start copy the Robot Controller System image to the disks. 6. Use the finished floppy disks to boot your system as described in section 4.4.

Figure 60 Select System

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3.7

RobInstall preferences1. To customise RobInstall for new programs and optional products, press Preferences (see Figure 61). See also chapter 6.

Figure 61 Customising RobInstall

2. To select another media pool (see section 6.1), press Select Media Pool (see Figure 62, position 1). 3. To add a new system package or option package to the media pool, press Import Program (see Figure 62, position 2). See also chapter 6.

1

2Figure 62 Select Media Pool/ Import Program

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Installation and Commisioning 44.1

Robot ControllerBootImageThe BootImage is a basic program which is used to start up the system from scratch. This program is already installed in the controller at delivery and is