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ABB IRB 2000, Product Manual

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7.1

Check list before startup

Before switching on the power, check as follows:

1. The mains supply fused rating.

2. The supply transformer in the cabinet is connected for the correct voltage.

3. The unused circuits in the safetychains must be closed by connecting jumpering:

Auto Stop: XS3 or XT3
Manual Stop: XS3 or XT3

General Stop: XS3 or XT3
Customer emergency stop XS3 or XT3

MOTOR OFF clamping device XS3 or XT3
External axes limit switches: XS3 or XT3

Ext.drive units POWER OK* XS3 or XT3

A3-A4andB3-B4
Al - A2 and Bl - B2
A5 - A6 and B5 - B6

A7 - A8 and B7 - B8,
A9 - A10 and B9-B10

Cl - C2 and Dl - D2

A l l - A 1 2 a n d B l l - B l 2

C12 - C16

4. If the controller includes the external axes option, check that the external axes

connections are made, or the following circuits are jumpered:

Motor PTC, axis 7: XS7
7th(-12th) axes limit switches: XS7

5. The programming unit is connected.

D1-D2
A4 - A5 and B4 - B5

6. The operation modeselector on the operating panel is set to MANUAL

<250 nun/8.

INSTALLATION

S3

7:2

Summary of Contents for IRB 2000

Page 1: ...0 ASEA BROWN BOVERI Configuration List Description IRB 2000 Safety Installation IRB 2000 Installation S3 Maintenance IRB 2000 Additional Documents Option RSI 3HAB 3HAB 3HAB 3HAB 3HAB 3HAB 0007 2 0001 2 0001 8 0003 2 0003 8 0005 2 ...

Page 2: ...Product Manual IRB 2000 3HAB 0007 2 January 1993 M93 ABB Robotics Products Jk It It ASEA BROWN BOVERI ...

Page 3: ...s document or of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB RoboticsProducts AB s written permission and the 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 Produc...

Page 4: ...arding con figuration and extent On delivery the complete document is placed in the robot control cabinet Till anvandaren Configuration List ar en individueli specifikation av det levererade robotsystemet avseende upp byggnad och omfattning Vid leveransen fran ABB Robotics finns det kompletta dokumentet inlagt i styrskapet IN THIS DELIVERY I Tested according to inspection provision 3HAA 3916 B App...

Page 5: ...Description IRB 2000 3HAB 0001 2 January 1993 M93 ABB Robotics Products A It It IPIP ASEA BROWN BOVERI ...

Page 6: ...s document or of the software and hardware described in this document This document and parts thereof must not be reproduced or copied without ABB RoboticsProducts AB s written permission and the 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 Produc...

Page 7: ...ly controlled functions System parameters TECHNICAL SPECIFICATION 5 1 5 2 5 3 5 4 Features 5 1 1 5 1 2 5 1 3 5 1 4 5 1 5 5 1 6 5 1 7 Performance Program capacity Battery capacity Signal capacity Man machine communication Working range Load diagram Requirements 5 2 1 5 2 2 Environmental requirements Electrical connections Physical data dimensional drawings 5 3 1 5 3 2 Physical data Dimensional draw...

Page 8: ...Description 1KB 2000 ...

Page 9: ...ding The handling capacity is 10 kg and the very quick movements of the wrist axes are other important features for the intended applications To make it possible to adapt the robot to various applications a range of peripheral equipment for various applications is available The peripheral equipment range includes tool exchangers gripper holders and several different gripper units Power and air sup...

Page 10: ...Description 1KB 2000 ...

Page 11: ...stem for process equipment and user wirings and pressurized air supply routed inside the robot arm All these integrated features when connected to peripheral equipment like grippers tool exchangers etc mean a reliable solution with high productivity Reliability and maintenance High quality characterizes the entire design e g few and rigid moving parts minimal maintenance robot wiring routed inside...

Page 12: ...Description 1KB 2000 6 ...

Page 13: ...l equipment Operator communication programming and manual running is performed via a portable programming unit Programming can also be performed off line via a terminal and an ABB Robotics Off line Programming Package CONTROL UNIT Programming unit Floppy disk unit Computer link Printout Power supply Power supply External I O External axes Track motion Tool interface j Manipulator PERIPHERAL EQUIPM...

Page 14: ...The brakes require no maintenance When the brakes are released the arm system may collapse Arm can make a sudden uncontrolled movement Gearboxes All gearboxes are made with very high accuracy and are specially adapted for each axis function All gears are lubricated with liquid grease and oil Cabling The cabling is highly modularised and therefore easy to replace as complete units The cables are ar...

Page 15: ...ower arm Axis 3 A Up and down movement of the upper arm Axis 4 D Turning of the complete wrist centre Axis 5 E Bending of wrist around the wrist centre Axis 6 P Turning of mounting flange robot turning disc 3rd A axis Motor unit Sth and 6th axes Motor unit 4th axis 6th E axis 6th PJ axis Wrist Motor unit and gear box 3rd axis Motor unit and gear box 2nd axis 1st C axis Base Gear box 1st axis Descr...

Page 16: ... for robot operation and programming Built in system test Handles storing loading of data on floppy disk Handles storing loading of data in a mass memory Recording duty time Additional display of user program and process messages Cooling of the electronic Control cable connection process communication computer link option program printout option Cooling device onitor Programming unit Fig 3 4 Contr...

Page 17: ...t peripheral equipment host computer option and floppy disc unit Contains all robot primary memory Contains circuits for personal safety functions emergency stop safe guarded stops limit switches etc Digital process communication Analogue process communication Contactors for power to the rectifier for the drive units and power for the brakes Voltage supply to drive units Stabilized voltage supply ...

Page 18: ...m The drive system for the robot motors and one integrated axis 7 option consists of the following units Computer board Rectifier unit Drive unit Serial measument board Control system for overall control for power supply to the drive units receives current references from the computer board The current references control the power amplifier supplying current to the motor reads the resolver Manipul...

Page 19: ...t Successful test running indicated by no red LEDs on all units a green LED lights up on the computer board Unsuccessful test running indicated by a red LED lights up on the faulty board if possible a fault message appears on the programming unit and on the monitor if installed Running of the control system in a special test mode during service with the following functions start up test full test ...

Page 20: ...Description 1KB 2000 14 ...

Page 21: ...gram edit and joystick run is not allowed Programming and program running with maximum speed 250 mm s Test run at maximum speed H MOTOR ON mode pushbutton MOTOR ON mode is indicated by light inside the button Indication External axis not synchronized by means of a twinkling MOTOR OFF light The robot motors are activated in the MOTOR ON mode MOTOR OFF mode pushbutton MOTOR OFF mode is indicated by ...

Page 22: ... when the operating mode selector is in one of the MANUAL positions All operator communications except selection of the operational mode for the robot are available on the portable programming unit The programming unit is provided with the following facilities for this purpose An illuminated two row alphanumeric display for messages in plain language The system can display texts in any of 10 langu...

Page 23: ...terrupting the running of the current program 2 Running a different program 3 Resuming the running of the current program A program which has been called up can in turn call up a third program etc up to 10 sub levels The built in floppy disk unit offers two possibilities Replacement of the whole program block All programs in the primary memory are replaced by a new block of programs downloaded fro...

Page 24: ...and the system can store a number of different TCPs in its memory The operator performs manual operation by using a joystick with three degrees of freedom The speed depends on the joystick deflection Manual operation During manual operation the robot axes are able to move in the following coordinate systems Rectangular base oriented coordinate system fixed coordinate system Axis oriented robot coo...

Page 25: ... position Each position is stored in the memory as the position of the TCP together with either the wrist orientation wrist oriented coordinate system or the tool orientation tool oriented coordinate system Three different types of automatic running are available Robot coordinate movement All axes are individually moved at constant speed towards the programmed position All axes reach their respect...

Page 26: ...te system TCP values absolute speed Displacement translation of a movement pattern by a reference point translation and rotation of a program by a reference frame Optional functions see chapter 6 Material handling Assembly Gluing Spot welding Arc welding Adaptive control The robot system can be controlled by sensors mounted on the robot or on the object The robot system can store signal data for a...

Page 27: ...ed coordinates The arguments are set during programming or brought up from a numerical register during programmed running Glue and Air flow if option 481 MH GL SW is selected Glue and Air flow reference signals are put out on two analog outputs at the same time as the robot is positioned Due to the lag in the robot movemnt and the delay in the gluing equipment there is also a delay function which ...

Page 28: ...instruction All of the necessary welding data is managed by the robot system The welding data has been separated into the following categories to make the system flexible and easily handled START DATA MAIN DATA END DATA WEAVE DATA SENSOR DATA Ten optional data fields can be defined simultaneously for each of these types The system is provided with integrated supervision of current gas flow and wat...

Page 29: ...etic Storage of TCP location and wrist orientation Other instructions Comments explaining program codes displaying execution status on the monitor option explaining program stops Gripper control 4 3 4 Editing functions Changing of Instruction Position by running the robot by entering the value Position of external axes Arguments in positioning instruction Searching for program or instruction by En...

Page 30: ... Initiating of floppy disk erasing of an old floppy disk Loading and storing of back up stored system parameters Erasing of block on floppy disk Superior computer control option Selection of running mode in relation to a superior computer control from computer or robot Storing of a program block in the computer Storing of a single program in the computer Loading of a program block from the compute...

Page 31: ...skette included in delivery To prevent loss of data the parameters can be stored as back up copies on floppy disk in a superior computer option The robot system also contains a default set of the system parameters stored in PROM These parameters allow the system to be operative before the installation adaption commences A number of the characteristics definable in the system parameters are Movemen...

Page 32: ...Description 1KB 2000 26 ...

Page 33: ...city Maximum load 10 kg Permitted load depending on distance from wrist see the load diagram section 5 1 7 Position resolution 0 125 mm Repeatability at mounting flange 0 1 mm 5 1 2 Program capacity Number of programs Main program number 0 1 Sub programs number definable 1 9999 Program memory Capacity 32 kword 64 kbyte Number of positions without supplementary information 1 6 axes max 2 500 7 9 ax...

Page 34: ...ignals Power Grounding Air connections foot R3 8 inner arm Rl 4 inner aprox 50000 hours 3 6 V lithium 5 years if environme temp 35 C 1000hrs 4Ah 5 years 50 C 18 hours 7 x 32 kword 448 kb 250 x 32 kword 0 96 inputs 0 96 outputs 0 4 inputs 0 4 outputs 24 6 1 1 50 V 250 mA 250 V 2 A Max 8 bar inner diameter 6mm Fig 5 1 Signal capacity 5 1 5 Man machine communication Programming method Point to point ...

Page 35: ...lectable Alphanumeric 2 rows 40 Numerical key pad 5 multi function keys Post PosS Posl Pos4 SYNC Se fig 1 POSITION 440 Rs520 Restricted working area Fig 5 2 Mazimum reach All dimensions in millimetres The restricted working area around the robot base is not limited by hardware of software but must be used since there is a risk of hitting the robot base The radius are measured to the centre line of...

Page 36: ...IS flgl J3ZM TO 535 2 Pbsi Fig 5 3 Position of the robot arm in its extreme positions All dimensions in millimetres Description 1KB 2000 30 ...

Page 37: ...5 1 7 Load diagram A X Mn 500 Fig 5 4 Permitted load as function of the location of the mass centre of gravity relative to robot mounting flange Description IRB2000 31 ...

Page 38: ...A A Fig 5 5 The cross lined area indicates centre of gravity allowed extra load at the mass point Description 1KB 2000 32 ...

Page 39: ...tions Power supply Mains voltage 200 600 V 16 A three phase Voltage tolerance 12 15 I O option can also be supplied from external voltage supplies for galvanic isolation See under Control system 150 Input output capacity Frequency 50 60 Hz Frequency tolerance 1 Hz Power consumption MOTOR ON program running 2 kW MOTOR OFF 300 W 5 3 Physical data dimensional drawings 5 3 1 Physical data Weight Manip...

Page 40: ...5 3 2 Dimensional drawings Description 34 1KB 2000 ...

Page 41: ..._200 _D D_ Description 35 1KB 2000 ...

Page 42: ...cabinet 1100 View from above Front view Space required If the free space gray zone around the cabinet is less than 100 mm a heat exchanger or air conditioner is necessary Cooling device Pockets for forklift Description 1KB 2000 36 ...

Page 43: ...mmon to CENELEC Comite Europe en de Normalisation Electrotechnique EN 60204 is common to all EEC and EFTA countries 5 4 2 Safety The robot is designed in accordance with the requirements of ISO 10218 Jan 1992 Industrial Robots Safety The robot also fulfils the requirements in the Manchinery Directive 89 392 EEC as defined in EN 775 October 1992 The robot also fulfil the ANSI RIA 15 06 1992 With th...

Page 44: ...Description 1KB 2000 38 ...

Page 45: ...apacity 6 2 Control system 130 Connection of mains supply The way the main voltage is connected to the control system can be selected from either permanent installation or with wall terminals on the left side of the cabinet 131 Cable bushing Connection is at the mains filter in the control cabinet the cable being led through a screw cap in the wall 11 12 mm diameter 131 132 Connection via wall ter...

Page 46: ...sformer 1 200 V 220 V Transformer 2 380 400 V 400 415 V 440V 475 V The robot can be connected to mains voltages between 200 V 600 V 3 phase protective earth Transformer 3 200 V 220 V 380 400 V 400 415 V 440 V 475 V 500 V 525 V 600 V Placing of operator panel The units for operator communication are an operating panel and a programming unit The operating panel the shelf for the programming unit and...

Page 47: ... axis 7 is designed for track motion IRBT 2000 3000S 192 Integrated axes 7 and 3 external axis Same as option 191 there 3 external axis can be driven 193 When all external axes drive units are installed outside the control cabinet up to 6 external axes can be driven A maximum motor speed of 3000 rpm is allowed Control L system MOTORS ON 1 MUIUHSUN 2 BRAKE Z POWER OK SPEED REF Drive unit A COARSE R...

Page 48: ...connected Rated voltage 24 V DC Current at rated input voltage 5 5 mA Outputs 16 opto connected short circuit protected Rated voltage 24 V DC Load capacity per output 200 mA Load capacity per group of 8 outputs 1A The unit is electrically divided into 4 parts with 8 inputs or outputs in each part Each part requires a separate voltage supply as follows in accordance with one of the following altern...

Page 49: ...t subsequent numbering of inputs and outputs Not valid if the function I O map have been used Remote panel Contents Inputs Outputs MOTOR ON MOTOR OFF FROM DISKETTE KEY locked programming unit LAMP TEST PROGRAM STOP PROGRAM START SYNCHRONIZE external axis MOTOR ON MOTOR OFF PROGRAM STARTED PROGRAM STOPPED FROM DISKETTE ERROR all errors including handling errors EMERGENCY STOP SYNCHRONIZE external a...

Page 50: ...ng on required number of grippers Location Sequential placing after chosen output for gripper 3 Digital gluing I O GL Contents Reservation Location Glue inhibit glue reference error 1 inputs 1 outputs Input 6 Output 7 SWI Spot Weld Interface SW Contents Control signals for welding controller outputs Start 1 Start 2 Current enable Weld power Reset Gripper 1 Gripper 2 Parity Weld program 1 Call weld...

Page 51: ... 4 outputs for control data 2 out 1 in for hand shake routines 6 outputs 5 inputs Output 1 6 and input 1 5 4 parallel output channels for 16 bit data words 2 out 1 in for hand shake routines 6 outputs 1 input Output 1 6 and input 5 227 Parallel I O ports 4 bit I O ports Quantity Location 8 bit I O ports Quantity Location Analogue I O unit with common 0 V Inputs Outputs 2 in and 2 out Input output ...

Page 52: ...ly are available in the system Reserved I O Reserved I O The following groups of analogue I O are reserved Analogue arc weld I O AW Analogue gluing I O GL The contents and meaning of the reservations are described below Analogue arc weld I O Contents voltage reference current reference Reserved 2 outputs Location output CHI and CH2 Analogue gluing I O Contents glue flow reference air flow referenc...

Page 53: ...emote link remote I O for communication with Allen Bradley PLC With the RIO function up to 128 inputs and outputs in groups of 32 I O can be transferred serially to a PLC control system equipped with Allen Bradley 1771 RIO node adapter Only digital system and remote panel signals can be transferred with RIO Connection to RIO is via screw terminals on the inside rear wall of the cabinet The RIO boa...

Page 54: ...s who do not desire plug in contacts there is the possibility of connecting signals apart from the robot s control signals to various types of screw terminals These are mounted on the rear inner wall of the control system The screw terminal units are mounted on mounting plates provided with cable channels and standard EN 50022 bars for attaching the screw terminal units The number of bars are matc...

Page 55: ...connected on a screw terminal unit as fig 6 9 This unit 3 is to be placed on the second bar to the left of the first digital screw terminal unit 58888888888888888886 588 888 888 888 888 88 8G Fig 6 9 Screw terminals unit 339 I O supply terminals 4 Provided with eight 2 A fuses for fuse protection of 24 V supply to I O etc As standard the fuses are connected to the control system s 24 V DC supply a...

Page 56: ...ard units is selected 34x Screw connection Digital I O 5 Up to 4 units see fig 6 9 are mounted on the same bar 36X Screw terminal connection with disconnect possibility for trouble shooting Up to 3 placed on the same bar Fig 6 12 Screw terminals unit with disconnect Description 50 IRB2000 ...

Page 57: ... screw terminal board All signals are connected to 64 pole contact units as per DIN 43652 with pin arrangement as per insulation manual S3 39x As in 38x above but where the user establishes the pin arrangement by filling in the wiring table 3HAB 2123 7 in conjunction with his order 400 ADDITIONAL EQUIPMENT The robot system can be supplied with any desired combination of additional equipment as fol...

Page 58: ...ter Link 403 Monitor LCD The control system can be supplied with a monitor All the electronics for the monitor is placed in the control cabinet The operator has access to the following functions from the monitor Display of parts of the current program with the activated instruction marked Activation of a new program or any new instruction is shown Valid program data are displayed above the actuate...

Page 59: ...ar inner wall of the cabinet The outlet is protected with a 2 A fuse All are provided with protective earth connection 421 230 V mains outlet as per DIN VDE 0620 Germany Sweden etc 422 230 V according to French standard 423 115 V Harvay Hubble 424 115 V according to British standard 425 115 V according to American standard Description 1KB 2000 53 ...

Page 60: ...abinet 432 Connection in front of the mains switch without transformer N B only for main voltage 380 V three phase with opt 153 neutral connection and service outlet for 230 V opt 421 422 Cannot be combined with CEE intake opt 132 133 since these intakes have no neutral connection 433 Connection in front of mains switch with transformer 380 V 500 V only together with opt 153 157 with secondary for...

Page 61: ...t is less than 100 mm The heat exchanger is working when the cabinet door is closed 444 Air conditioner The control cabinet can be fitted with a fixed air conditioning unit The air conditioning unit is required to keep a temperature below 45 C inside the control cabinet if the ambient temperature is below 45 C The air conditioner is working when the cabinet door is closed 480 Program versions In a...

Page 62: ...ipulator and the control system is available in following version 7m 15 m Extension cable to the programming unit Length 10 m To be connected between the control system and the existing contact on the programming unit s cable Not more than two extension cables should be used i e a total length of 30 m between the control system and the programming unit CUSTOMER CONNECTIONS Connectors Industrial co...

Page 63: ... control system incl circuit diagram S3 Service Manual IRB 2000 Introduction Maintenance Mechanical repairs Spare parts list Circuit diagram The following language alternatives are available No documentation 702 English 703 Swedish 740 EXTRA DOCUMENTATION Any number of extra copies of the above documents can be supplied with the robot 74x Service manual S3 and Service manual IRB 2000 75x Programmi...

Page 64: ...Description 1KB 2000 58 ...

Page 65: ...3HAB 0001 8 JANUARY 1993 M93 Safety IRB 2000 IRB 3000 IRB 3200 IRB 6000 A It It ABB Robotics Products ASEA BROWN BOVERI ...

Page 66: ...INTRODUCTION Apart from the built in safety functions in the industrial robot itself the robot also has electrical inputs and outputs for the connection of external safety devices Through these electrical inputs and outputs the robot interacts with other machines and peripheral equipment This means that control signals can initiate safety functions from the peripheral equipment as well as from the...

Page 67: ... be the normal position when entering into the working space The MANUAL FULL SPEED position allowing full speed may only be used by trained personnel who are aware of the risks that this entails During programming and testing the robot system is to be in the MOTOR OFF enabeling device released mode to ensure that the robot is not moving The use of MOTOR ON enabeling device de pressed mode to move ...

Page 68: ...it It must be necessary to reset the power before any robot motion can be initiated Resetting of the power by the safety stop itself must not initiate any motion 4 4 Reduced speed ISO 10218 3 2 17 A single selectable velocity defined by the robot manufacturer which automatically restricts robot velocity so as to allow sufficient time for persons either to get clear of hazardous robot movements or ...

Page 69: ...er supplied to the motors THE ELECTRICAL SAFETY CHAINS OPERATING MODE SELECTOR 24V OV AUTO MANUAL REDUCED SPEED MANUAL FULL SPEED GS ES LJMSW COMPUTER OUTPUTS ENABLE MOTOR ON GS ES LIMSW ENABLE MOTOR ON MCI B MC2 B OV 24 V AS AUTO MODE SAFEGUARDED SPACE STOP MS MANUAL MODE SAFEGUARDED SPACE STOP GS GENERAL MODE SAFEGUARDED SPACE STOP ES EMERGENCY STOP BUTTONS MCI MOTOR CONTACTOR 1 MC2 MOTOR CONTAC...

Page 70: ...h clear cut positions One auto and two manual modes are available AUTO Automatic operation 250 mm S MANUAL Programming Adjustment at reduced speed 100 MANUAL FULL SPEED Test at working speed For automatic operation with the key switch in AUTO position all safety arrangements such as doors gates light curtains light beams and sensitive mats etc must be active No person must be present inside the sp...

Page 71: ...ot is used must always be observed Automatic operation key switch in AUTO position Automatic operation can be started when the following conditions are fulfilled Key switch in AUTO position MOTOR ON mode selected The robot s external axes are synchronised The program can be started from the teach pendant or through a connected remote control device These functions should be wired and interlocked i...

Page 72: ...teach pendant 5 1 5 Connection of GENERAL MODE SAFEGUARDED STOP GS The GS connection is provided for interlocking of 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 opened the robot changes to MOTOR OFF mode To reset to MOTOR ON mode the device which initiated the safety ...

Page 73: ...d out by the user see Installation Manual 5 2 Supplementary functions Functions via specific digital inputs Stop through program interrupt or instruction interrupt can be activated through connections to digital inputs These inputs can be used to stop programs in the event of a fault in the peripheral equipment for example Calling a program programs 1 5 can be initiated through digital inputs dire...

Page 74: ... hydraulic systems must be released before repair work is commenced on them Gravity may cause any parts or objects which are 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 Actions during operation disturbances Disturbances in the working process entail other risks besides those associated with...

Page 75: ...ble devices for such arrangements By means of suitable arrangements such as use of turntables or the like the operator should be kept away from the robot s working space Persons responsible for operations must make sure that safety instructions are available at the installation in question Persons involved in the installation must be trained in the robot system in question and in safety matters as...

Page 76: ...om mains Additional connections Manipulator Dangerous voltage may be present on the robot at The power supply for the motors to 340 VDC User connections for tools or other parts of the installation see Installation max 220VAC 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 du...

Page 77: ...Safety 1KB 2000 IBB 3000 12 1KB 3200 1KB 6000 ...

Page 78: ...Installation IRB 2000 3HAB 0003 2 January 1993 M93 0 1 JIM ABB Robotics Products ASEA BROWN BOVERI ...

Page 79: ...Mounting 3 2 Foundation loads 3 3 Suspended mounting 3 4 Required space 4 5 6 7 8 9 Manual release of brakes Working range limitations 5 1 Axis 1 5 2 Axis 2 5 3 Axis 3 Customer connections Connections to the control cabinet Calibration positions Running the robot 11 13 17 19 21 27 Installation 1KB 2000 ...

Page 80: ...Installation H B 2000 ...

Page 81: ...erences to the following documents not included Circuit diagrams IRB 2000 Description IRB 2000 Service manual IRB 2000 Programming manual S3 IMPORTANT Before unpacking and installation study the safety regulations and remaining instructions carefully These are found in the Installation Manual of the Control cabinet S 3 Installation IRB 2000 ...

Page 82: ...Installation 1KB 2000 ...

Page 83: ...storage If the equipment is not to be installed immediately all units are to be stored in a dry area with an ambient temperature of 25 C to 55 C The total weight of the robot is approx 350 kg The recommended method for lifting the robot is to use slings and an overhead crane Attach the slings to the lifting lugs on the inside of the gearboxes of axes 2 and 3 The dimensions of the slings must compl...

Page 84: ...es 2 and 3 Use a fork lift or an overhead crane to lift the robot The figure below shows the robot with its axes positioned as they are on delivery which is also the recommended position when transporting the robot Instructions for changing the positions of the axes are given in Section 4 Manual release of brakes NOTE Take extreme care when transporting and handling the robot Installation 1KB 2000...

Page 85: ...xes 2 and 3 Use a fork lift or an overhead crane to lift the robot The figure below shows the robot with its axes positioned as they are on delivery which is also the recommended position when transporting the robot Instructions for changing the positions of the axes are given in Section 4 Manual release of brakes NOTE Take extreme care when transporting and handling the robot Installation 1KB 200...

Page 86: ...pattern shown below using 3 x M16 screws tightening torque 190 Nm 19 5 kpm oil lubricated screws The level requirements of the surface are Where accurate adjustment of the robot base and the ability to remount the robot without program adjustments are called for a special fixing kit can be used see Description IRB 2000 Follow the instructions included in the kit EsD Installation IRB 2000 ...

Page 87: ...uspended Moment Mxy Mz Fatigue load Operation 1600 N 3500 1000N 3500 1000N 3100 Nm 600Nxn Max load Emergency stop 2900N 3500 1900N 3500 1900 N 5300Nm 1500 Nm Fxy resp Mxy refers to a arbitrary directed vector in the xy plane z Installation IBB 2000 8 ...

Page 88: ...ded position is basically the same as for floor mounting With inverted installation make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections so that optimum performance can be achieved Installation 1KB 2000 ...

Page 89: ...ng range are shown below The working range of the axis 1 C is 179 9 NOTE There are no software or hardware limitations for the robot working range closest to the robot base see Description IRB 2000 NOTE Centre line of axis 5 Installation IRB 2000 10 ...

Page 90: ...below Axel 6 P c OV 814 24V B16 _g 8 TCL When the control system or the power supply mentioned above is connected the robot axes can be released individually by pressing the corresponding button on the gearbox of axis 3 The buttons are marked with the relevant axis number The illustration below shows the locations of the brake release button the axis designations and motions WARNING Be careful whe...

Page 91: ...Installation 1KB 2000 12 ...

Page 92: ...of the main axes 1 and 2 and limit switch installed on axis 3 5 1 Aarisl Axis 1 normally operates within a rotational movement of 179 9 This area can be mechanically limited by fitting stops to the intermediate plate These stops can limit the robot working range infinitely variable The fitting of stops are described in the erections provision delivered with the kit NOTE The original stop must unde...

Page 93: ...imit the arm movement by increments of 30 30 lstop 60 2 stops etc Fit the stop to the stop ring using screws M8 x 30 NOTE The edges of the stop are slightly tapered casting draft angle so they must be turned in the right way round for a snug fit on the surface of the stop ring Additional stops can be fitted by 30 increments to achieve the desired limits Installation 1KB 2000 14 ...

Page 94: ...cribed in the erections provision included in the kit Axes 3 limit in proportion to floor level When altering the mechanical limitation of the working range remove the switch acti vator segment by removing the three screws holding it Then refit the segment in a suit able position on the disc giving the desired working range limitation Secure the screws with LocTite 242 or corresponding Also see th...

Page 95: ...Installation 1KB 2000 16 ...

Page 96: ...the fixing holes for customer applications basic version as well as air and electrical connections Numbers in boxes indicate 1 2 Customer connection Burndy round 12 pole plug UTG 014 12 S 2x option Connection to air Rl 4 Customer connection Burndy round 12 pole plug UTG 014 12 S lx option 3 Hole for air connection inside R 3 8 Max 8 bar option The connectors are connected according to the robot Ci...

Page 97: ...r No UTO 614 12PN04 and two for the signal connectors Adapter Burndy 12 poles No UTG 12AD Same as above ABB Article No 3HAA 2602 2 3HAA 2601 2 Shrink boot Hellerman 12 pole No 1103 4 B5 WM250 Pin AWG26 24 AWG22 20 AWG20 16 Same as above 5217 1032 4 5217 649 72 5217 649 70 5217 649 68 Earth pin AWG26 24 AWG20 16 5217 649 10 5217 649 31 No of used power and signal connductors Installation 18 IRB2000...

Page 98: ...h two connectors The right hand connector as seen from behind carries power to the motors etc and the left hand connector carries signals between robot and control cabinet Detailed information about this is given in the Installation Manual of the control cabinet Installation S3 Installation 1KB 2000 19 ...

Page 99: ...robot manually using the joystick to a position where the calibration marks are within the tolerance zone as shown in the figure on the next page The axes are to be adjusted in increasing sequence i e 1 2 3 4 5 6 Axes 5 or 6 must not be manually moved before the robot is calibrated to avoid that the resolver of axis 6 is calibrated on the wrong resolver revolution When calibration is performed as ...

Page 100: ...1 mm tolerance zone 1 mm toleransomrade 6 mm Hem 1 and 2 Calbration pin Item 3 M6x40 Pos 1 och 2 Kalbreringspinne Pos 3 M6x40 Installation 21 IBB 2000 ...

Page 101: ...tive calibration positions must be done before the installation of the robotsystem if the final installation prevents that calibration position 0 is used The different alternative calibration positions are described in the Installation Manual of Control System S3 After setting any of the above alternative calibration positions the revolution counter value is to be stored by giving the following co...

Page 102: ...Axis Calibration position see figure below 0 1 2 3 4 5 1 0 90 90 0 90 90 2 0 0 0 90 90 90 3 0 0 0 90 90 90 Sync pocnai Installation 1KB 2000 23 ...

Page 103: ...rogram according to section 8 2 Start the program and switch the robot to the STANDBY mode when it has been calibrated Check that the calibration marks align with eachother At check with the electrical inclination instrument should the result be within 0 5 mm m using the systemdisc Installation 1KB 2000 24 ...

Page 104: ... are thoroughly described in the Programming Manual Before starting the robot check that there is no danger of the robot running into any obstacles especially if the robot system is equipped with external axes track motion or similar Installation 1KB 2000 25 ...

Page 105: ...3HAB 0003 8 January 1993 M93 INSTALLATION Robot control system S3 Ml It It ABB Robotics Products ASEA BROWN BOVERI ...

Page 106: ...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 v written permission and the 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 Produ...

Page 107: ...OTOR ON OFF operating circuits 3 4 4 Connection tables external signals 3 4 5 Technical data external signals 3 4 6 External safety relay 3 5 Safety stopsignals 3 12 3 5 1 Category 1 safety stop 3 6 Voltage supply to electronics 3 13 3 6 1 24 V I O 3 6 2 External supply 3 8 Connection of user equipment to the robot option 3 14 3 8 1 IRB2000 3 8 2 IRB3000 3 8 3 IRB3200 3 8 4 IRB6000 3 9 Sensors int...

Page 108: ...re start up 4 3 4 3 Start up to standby 4 3 5 SYSTEM PARAMETERS 5 1 5 1 Introduction 5 1 5 1 1 Handling system parameters 5 1 2 Handling parameter menus 5 1 3 Handling stored parameters to from a diskette 5 1 4 Handling stored parameters to from a superior computer 5 1 5 Concluding procedures 5 2 Individual system parameters 5 6 5 2 1 Parameters menus and submenus 5 2 2 Loading parameters from a P...

Page 109: ...nal axis 7 6 5 3 Position control 6 5 4 Handling of the programming unit 6 5 4 1 Test signal configuration 6 5 4 2 Trimming function 6 6 Adjusting sync swithches and absolute measurement 6 22 7 QUICK START UP AND PARAMETER INDEX 7 1 7 1 Check list before startup 7 2 7 2 Start up to standby 7 3 7 3 Test running 7 4 7 4 Coupling diagrams 7 5 8 SYSTEM DISC 8 1 8 1 Robot System parameters 8 1 SJZ Erro...

Page 110: ...INSTALLATION S3 0 4 ...

Page 111: ...1 SAFETY INSTRUCTIONS AND RECOMMENDATIONS See separate document in the Product manual INSTALLATION S3 1 1 ...

Page 112: ...INSTALLATION S3 1 2 ...

Page 113: ...control system is shown in the figure below 1100 View from above Front view Space required If the free space gray zone around the cabinet is less than 100 mm a heat exchanger or air conditioner is necessary Cooling device Bars for forkiift INSTALLATION 2 1 ...

Page 114: ...fil the requirements of NEMA 12 Avoid however spraying the control cabinet with water or other liquids The control cabinet and its contents withstand shocks due to the normal transport in accordance with IEC 68 2 6 IEC 68 2 29 If the floor on which the cabinet is to stand permanently is subject to vibration the cabinet should be mounted on shock absorbing vibration dampers If the plant has a histo...

Page 115: ...ith Control signals screened cables Measurement signals screened cable with twisted pairs Data communication signals screened cable with twisted pairs 3 1 2 Routing Power signals these signals cause high disturbance and are to be contained in a separately screened cable The screening is to be clamped against a surface free of paint on the steel frame of the cabinet Control signals These signals ar...

Page 116: ...he coil A varistor give a shorter realeasing time Diodes and RC filters can be replaced with varistors A varistor gives a shorter delay The suppression of coils also extends the service life of the switches which control the coils Examples of how to suppress peripheral equipment connected to the robot system 24VDC ov 24 V DC or ACvoltage The diode is to be dimensioned for the same current as the r...

Page 117: ...n of signal cables Fold unused conductors backwards and fix to the cable with cable ties Check that the conductors are not connected at the other end of the cable to avoid interference aerial effect or cross talk If there is risk of interference unconnected conductors should be connected to ground 0 V The following applies when contact pressing connections in and industrial connectors A crimp cont...

Page 118: ...nnector accomodates 4 rows of 16 conductors with a maximum conducting are 1 5 mm2 The screen must be fixed with the upper part of the connector All industrial connectors in the customers cables are pin connectors the cabinet are deliveryed with housing connection Article No ABB 5217 687 24 5217 687 21 5217 687 9 5217 1021 1 5217 1021 2 2 100 100 Article No Amphenol C146 10A064 000 2 C146 10G064 50...

Page 119: ...rminal XT 3 XT 11 XT 12 XT 13 XT 14 XT 15 XT 16 XT 10 Connector terminal XS XP3 XS XP11 XS XP12 XS XP13 XS XP14 XS XP15 XS XP16 XS XP7 XS XP10 XS XP4 Signal identification Safety stops 24 V sensor etc Digital I O 1 Digital I O 2 Digital I O 3 Digital I O 4 Digital I O 5 Digital I O6 External axes Analog I O External axes Example of the terminals on the rear wall of the cabinet is shown below Incom...

Page 120: ... to the control cabinet via two cables one cable for measurement signals and one cable for the motor drives The measurement and motor cables are connected to the left hand side of the control cabinet at one industrial type connector and one Burndy type connector The measurement and motor cables are connected to external contacts at the rear of the robot base See following figure XS2 1 XS2 It s for...

Page 121: ... MOTOR OFF Any difference in the two chains will maintain the MOTOR OFF condition The principal for one circuit with possible customer connected switches AS MS GS and ES is shown in figure below Operating mode selector AS MS GS ES Automatic mode safeguarded Stop Manual mode safeguarded Stop General mode safeguarded Stop Emergency Stop INSTALLATION 3 7 ...

Page 122: ...ECTOR ES PANEL ES TEACH PENDENT EXT ES2 EXT LJMSW2 MOTOR ON PB LIMSW2 _J 1 D6 D5 D4 JC6 C5 rC3 T53 XS External connector XT Screw terminal SYSTEM BOARD I I 24V I I BRAKE CONTACTOR MOTOR CONTROL E 3BRAKE l _ _ _ I _ _ _CQNTEOLj MOTOR CONTACTOR 2 MOTOR CONTACTOR 1 CIO C l l l B13 A14 INSTALLATION 3 8 S3 ...

Page 123: ...2 General Stop 2 E stop buttons 1 E stop buttons 1 E stop buttons 2 E stop buttons 2 Ext E stop 1 Ext E stop 1 Ext E stop 2 Ext E stop 2 Note A7 A8 A9 A10 B7 B8 B9 B10 have to be jumpered for proper function of control system s E stop buttons Ext limit switch 1 Ext limit switch 1 Ext limit switch 2 Ext limit switch 2 ESTOP 1 EXTUM1 ESTOP 2 EXTLIM2 MOFF HOLD 1A MOFF HOLD IB MOFF HOLD 2 OV All A12 B...

Page 124: ...C5 C6 D3 D4 D5 D6 A13 A14 B13 B14 CIO Cll Note External using of operating mode selector Chain 1 External using of operating mode selector Chain 2 Motor contactor 1 Motor contactor 1 Motor contactor 2 Motor contactor 2 Brake contactor Brake contactor 3 4 5 Technical data external signals Max voltage Max current BRAKE Max current others Max potential in relation to control system earth Signal class...

Page 125: ...afety relay The emergency stop buttons in the control system can operate together with external emergency stop buttons using an external safety relay External safety relay s I To customer equipment INSTALLATION 3 11 S3 ...

Page 126: ...tops are of category 0 A category 1 safety stop is achieved by using the HOLD 1 2 function together with AS orGS 3 5 1 Category 1 safety stop soft stop HOLD 1 and HOLD 2 connected to gate closed contacts supplied by 24V will at contact opening order PROG STOP and short there after two relay contacts are opened These relay contacts can be connected in any of the MOTOR ON OFF user switch positions A...

Page 127: ...es The internal supply provides too little current Galvanic isolation is necessary because of the risk of interference through ground currents Galvanic isolation is necessary because of the difference in potential between the control signal and the chassis ground Galvanic isolation is required for reasons of safety Risk of the transmission of considerable interference into the internal 24 V supply...

Page 128: ...the manipulatom option Techincal data for user connection Power supply Conductor resistance 0 5 ohm 0 241 mm2 Max voltage 250 VAC Max current 2 A Signals Conductor 3 ohm 0 154 mm2 Max voltage 50 VAC DC Max current 250 mA INSTALLATION 3 14 ...

Page 129: ...JC42 B R X42 C R X42 D R X42 E R X42 F R X42 G R X64 H R X42 J R X42 K R X42 L R X42 M R X43A R X43 B R X43 C R X43 D R X43 E R X43 F R X43 G R X43 H R X43J R X43 K R X43 L R X43 M CC1 A CC1 B CC1 C CC1 D CC1 E CC1 F CC1 G CC1 H CC1 J CC1 K CC1 L CC1 M CC2 A CC2 B CC2 C CC2 D CC2 E CC2 F CC2 G CC2 H CC2 J CC2 K CC2 L CC2 M 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 XT2 1 XT2 2 XT2 3 XT2...

Page 130: ... CC2 MQ2 INSTALLATION User contact on robot XS1 C8 XS1 C9 XS1 C10 XS1 C11 XS1 C12 XS1 C13 XS1 D4 XS1 D5 XS1 D6 XS1 D7 same number within brackets XT2 1 XT2 1 XT2 3 XT2 4 XT2 5 XT2 6 XT2 7 XT2 8 XT2 9 XT2 10 XT2 11 XT2 12 XT2 13 XT2 14 XT2 15 XT2 16 XT2 17 XT2 18 XT2 19 XT2 20 XT2 21 XT2 22 XT2 23 XT2 24 User contact X80 A X80 B X80 C X80 D X80 E X80 F X80 G GROUND X80 H KEY PIN X80 J X80 K X80 L X...

Page 131: ... number within brackets are twisted pairs CC1 AU CC1 B 1 CC1 C 2 CC1 D 2 CC1 E 3 CC1 F 3 CC1 G 4 CC1 H 4 CC1 J 5 CC1 K 5 CC1 L 6 CC1 M 6 CC2 A 7 CC2 B 7 CC2 C 8 CC2 D 8 CC2 E 9 CC2 F 9 CC2 GU0 CC2 H 10 CC2 J 11 CC2 K 11 CC2 L 12 CC2 M 12 XT2 1 XT2 2 XT2 3 XT2 4 XT2 5 XT2 6 XT2 7 XT2 8 XT2 9 XT2 10 XT2 11 XT2 12 XT2 13 XT2 14 XT2 15 XT2 16 XT2 17 XT2 18 XT2 19 XT2 20 XT2 21 XT2 22 XT2 23 XT2 24 X86...

Page 132: ...3 XT6 4 XT6 5 XT6 6 XT6 7 XT6 8 XT6 9 XT6 10 User contact on robot R3 CPA R3 CP B R3 CP C R3 CP D R3 CP E R3 CP F R3 CP G GROUND R3 CP J R3 CP K R3 CP L R3 CP same number within brackets are twisted pairs XT5 1 XT5 2 XT5 3 XT5 4 XT5 5 XT5 6 XT5 7 XT5 8 XT5 9 XT5 10 XT5 11 XT5 12 XT5 13 XT5 14 XT5 15 XT5 16 XT5 17 XT5 18 XT5 19 XT5 20 XT5 21 XT5 22 XT5 23 R3 CSA R3 CS B R3 CS C R3 CS D R3 CS E R3 C...

Page 133: ... included in the system software The sensors are connected to the control cabinet via inputs on the circuit boards in accordance with the table SENSOR Digital one bit sensor Digital two bit sensor Digital two bit sensor Analog sensor FUNCTION Distance searching Distance searching Speed control Distance searching Direction searching Speed control Contour tracking Distance searching Direction search...

Page 134: ... I O Sensor inputs on the system board cannot cope with input signals with pulse widths between 0 2 and 4 ms It is therefore important to use transducers with hysteresis intended for industrial environments Certain proximity transducers can give showers of pulses where they are at the change over point or if the supply voltage is disturbed CONNECTION TABLE Signals from one bit sensors via the safe...

Page 135: ...3 10 I O option The figure below shows the control cabinet boards both the basic version and options available POSITION DESIGNATION I O DESIGNATION so O 5 s OPTIONAL BOARDS INSTALLATION 3 21 ...

Page 136: ...etween PREDEF and I O MAP1 NOTE When you push PREDEF and the BREAK ACTIVE you will have the predefined in and outputs activated When you push I O MAP and the BREAK ACTIVE the I O MAP is activated PREDEF PREDEF The I O boards are numbered from right to left The logical numbering is 1 128 for inputs and outputs The relation between physical inputs outputs and logical inputs outputs is not dependant ...

Page 137: ... system or panel input before Unking it to an output To change a link first clear the linked I O table and then define all desired links again It is possible to link more than one output to the same input Up to 15 links are allowed NOTE If I O MAP is used all digital inputs and outputs must be defined on defined digital boards in the system It is adviseable to note on paper all mapped and linked I...

Page 138: ... 83 C3 D3 A4 B4 C4 D4 A5 B5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8 B8 C8 D8 A9 B9 C9 D9 A10 BIO CIO D10 All Bll Cll Dll A12 B12 C12 D12 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 XT1 201 XT1 202 XT1 203 XT1 204 XT1 205 XT1 206 XT1 207 XT1 208 XT1 U1 XT1 209 XT1 210 XT1 211 XT1 212 XT1 213 XT1 214 XT1 215 XT1 216 XT1 U2 XT1 XT1 14 12 XT1 24 22 X...

Page 139: ...d interpreted correctly by the system POMAK When system I O under I O MAP is used also the following functions are available SYSTEM AUTO The output SYSTEM AUTO is set when all of the following are set Key switch is in AUTO No Emergency stop AUTO INPUT is trigged It is reset when any of the three first conditions is not true or a error code appears HOLD RESET HOLD EXTERNAL HOLD RESET HOLDr HOLD ACK...

Page 140: ...it see 3 10 3 XT 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40 Note If flexible I O I O MAP is used all in and outputs above are available under SYSTEM or PANEL menus INPUT CH 9 INPUT CH 10 INPUT CH 11 INPUT CH 12 INPUT CH 13 INPUT CH 14 INPUT CH 15 INPUT CH 16 U2 U4 OUTPUT CH 9 OUTPUT CH 10 OUTPUT CH 11 OUTPUT CH 12 OUTPUT CH 13 OUTPUT CH 14 OUTPUT CH 15 OUTPUT CH 16 U4 Function Interr...

Page 141: ...G START lamp SYNC lamp MOTOR OFF lamp PROG STOP lamp FROM DISK lamp ERROR lamp EMERGENCY STOP lamp 0 V supply to group 3 XS B3 C3 D3 A4 B4 C4 D4 A5 B5 A8 B8 C8 D8 A9 B9 C9 D9 A10 BIO XT 2 3 4 5 6 7 8 9 10 21 22 23 24 25 26 27 28 29 30 Remark Active only in AUTO Active only in AUTO Active only in AUTO Active only in AUTO Above logical inputs and outputs are available when system I O under I O MAP i...

Page 142: ...affected The port can contain 4 inputs outputs ports 11 12 1 and 2 or 8 input outputs ports 13 4 3 and 4 There are also two sequential ports 70 and 80 which embrace both inputs and outputs Possible couplings between inputs outputs and ports 1 4 or ports 11 14 are shown in the table below LSB means Least Significant Bit and MSB means Most Significant Bit Port no Logical output Port no Logical input...

Page 143: ...utputs depending on how many other digital I O boards that are installed in the system The maximum number of digital in and outputs the system can handle is 128 The board should be placed to the left of the last I O board in the frame this gives the most freedom to choose configuration on the RIO board On the front of the board there are 32 leds The first 16 is used to indicate status for the firs...

Page 144: ...t The analog I O board is placed on I O board position KD26 168 but connected to a separate contact The analog inputs and outputs in the robot system can be supplied with an internal 15 V voltage from the control cabinet or with an external 15 V voltage When internal 15 V voltage is used there is no galvanic isolation between the analog inputs outputs and the control cabinet electronics The functi...

Page 145: ...orts 1 Mohm 10 V 10 mV 10 1024 V 15 mV 0 2 of input signal 10 V 2 kohm 10 mV 10 1024 V 25 mV 0 45 of output signal 20 mA 450 ohm 20 uA 20 1024 mA 60 uA 0 5 of output current 14 3 15 7 V 15 V 240 mA 500 V for a maximum of 1 minute 50 V continuously Measurement signals The physical input output signals are coupled logically to different ports A port is the robot system designation of analog inputs o...

Page 146: ...d to C5 ll II Internally connected to A5 9 14 15 V supply of analog I O Internally connected to A6 13 13 15 V supply of analog I O Internally connected to B6 14 18 15 V supply of analog I O Internally connected to A7 17 17 15 V supply of analog I O Internally connected to B7 18 16 0 V supply of analog I O Internally connected to C6 15 15 0 V supply of analog I O Internally connected to D6 16 The f...

Page 147: ...m the control cabinet or with an external 15 V voltage When internal 15 V voltage is used there is no galvanic isolation between the analog outputs and the control cabinet electronics Technical data Digital input output for each group of 8 channels Inputs Optoinsulated Rated voltage 24 V DC 45 20 Input current at rated voltage 5 5 mA Min 15 V gives 1 closed input Max 5 V gives 0 open input Outputs...

Page 148: ...o group 3 0 V supply to group 3 24 V supply to group 4 0 V supply to group 4 Terminal XS11 B3 C3 D3 A4 B4 C4 D4 A5 B5 D5 A6 B6 C6 D6 A7 B7 C7 D7 AS B8 C8 D8 A9 B9 C9 D9 A10 BIO CIO D10 All Bll Cll Dll A12 B12 C12 D12 XT11 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Logical input 1 Logical input 2 Logical input 3 Logical input 4 Logical ...

Page 149: ...5 Port 21 Normally voltage reference in AW systems Port 22 Normally current reference in AW systems 15 V supply of analo EXT 15V EXT 15 V connected EXT 15 V connected 0V OV External supply 15 V A6 External supply 15 V B7 External supply 15 V A7 0 V external supply D6 0 V external supply C6 outputs Internally connected to eachother A6 13 13 15 V supply of analog outputs Internally connected to each...

Page 150: ...voltages The internal 15 V 15 V and 0 V may only be used for voltage supply of the analog I O board INT 15 V Internal supply 15 V D8 24 Strapped to a B6 and orA6 14 13 INT 15 V Internal supply 15 V C8 23 Strapped to a B6 and orA6 14 13 INT 15 V Internal supply 15 V B8 22 Strapped to a B7 and orA7 18 17 INT 15 V Internal supply 15 V A8 21 Strapped to a B7 and orA7 18 17 OV OV D7 20 Strapped to D6 a...

Page 151: ...olled with external axes and common drive units see chapter 6 External axes The use of these boards is described in the Programming Manual Weld start Logical output 9 Gas on Logical output 7 Voltage on Logical output 8 Wire feed on Port 21 Welding voltage reference Port 22 Welding current reference Wire speed Robot movement Weld end Inactive signal or activity Gas pre flow Ignition incl possible s...

Page 152: ...T 14 OUTPUT 13 and AXES 7 AXES 8 9 AXES 10 11 AXES 12 The axes 8 and 9 and 10 and 11 respectively share two drive units which means that the stations B and C cannot be active simultaneously this is marked with a In this case the synchronized sequence is 1 C robot 2 B A D robot 3 B D are deactivated so that only A is active after the synchronization A switchover from station to C is illustrated by ...

Page 153: ...nput is monitored during the weld start during the welding and during the filling time An active signal indicates a satisfactory welding current If the signal disappears welding in progress is interrupted an error message is presented and the robot stops Wire feed on The input is only activated for manual feed of a new welding wire Process off The input is activated to block the welding during the...

Page 154: ...n in accordance with the function parameter STATION Analog or combined arc weld I O The following input outputs are default for arc welding functions in an IRB 2000 AW robot system Contacts and outputs are presented in the connection table for the analog I O board in section 3 11 2 and for the combined I O board in section 3 11 4 Other ports can be chosen using the system parameters Analog input o...

Page 155: ...nal class Data communication signals 2 The parameters for the robot must be correctly defined see chapter 6 System parameters 3 The printer terminal must have the following technical data Signal interface V24 RS232C Transmission speed 300 1200 baud Word length 8 bits Parity None Stop bit 1 bit For a more detailed description of the function see the Programming Manual Note At a transmission speed o...

Page 156: ...d jumper D to E J DTR if DTR RLDS and DSR are not used jumper J H and F together H RLDS if DTR RLDS and DSR are not used jumper J H and F together F DSR if DTR RLDS and DSR are not used jumper J H and F together M RI L Signal Ground K Ground shield Signal class Data communication signals 2 The communication parameters for the robot system must be correctly defined see chapter 6 System parameters 3...

Page 157: ...trips screws etc and to be mounted together in an external panel enclosure Cover plates are mounted on the control system The external panel enclosure must be in accordance with the requirements of IEC 144 and IEC 529 Degree of protection rating IP 54 NEMA12 See the dimensioned figure below for the mechanical assembly 58 18 54 202 34 5 D 3 4 x4 2 Hole for LCD monitor option 320 224 max 3 Hole for ...

Page 158: ...ed by a flange witch shoulk be mounted in the external panel enclosure See the figure below for the princible connections External panel enclosure Operating panel Control system left side Cable glands Programming unit connector INSTALLATION S3 3 44 ...

Page 159: ... An example of reserved inputs and outputs for the SWI function if the board is placed in the second space Flexibel I O INPUT 1 2 3 4 5 6 WELD READY TIMER OK CURRENT OK FLOW OK TEMP OK ENABLE MOVE OUTPUT 1 2 3 4 5 6 7 8 START 1 START2 CURRENT ENABLE WELD POWER RESET GRIP1 GRIP 2 PARITY no 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 cl 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 ch no 9 10 11 12 13 14 15 1...

Page 160: ...INSTALLATION 3 46 ...

Page 161: ... 6HsB can be use Connection according to circuit diagram in S3 Service Manual Top left hand side of controller 4 1 1 Connection on left hand side Pass a sufficient length of the mains supply cable through the gland to permit connection to the line filter Then tighten the gland To work with the line filter you need to take avay protection cap The mains voltage is connected to the line filter inside...

Page 162: ...BOT TYPE 1KB 2000 3X00 IRB6000 MAINS VOLTAGE TRANSFORMER 3HAA 3101 CB 200V 220V CC CE 380V 400V 400V 415V 400V 475V CD 200V 220V 380V 400V 400V 415V 440V 475V 500V 525V 600V CF 200V 220V 500V 525V 600V JUMPERS 1 21 2 31 3 11 1 22 2 32 3 12 1 23 2 33 3 13 1 24 2 34 3 14 1 25 2 35 3 15 1 61 2 71 3 51 1 62 2 72 3 52 1 63 2 73 3 53 1 64 2 74 3 54 INSTALLATION 4 2 ...

Page 163: ... 7th 12th axes limit switches XS7 A4 A5 and B4 B5 5 The programming unit is connected 6 The operation modeselector on the operating panel is set to MANUAL 250 mm s 4 3 Startup to standby 1 Make sure the cabinet door is closed 2 Switch the power on 3 The MOTOR OFF lamp on the control panel illuminates when the system has completed the hardware and software diagnostic test This test lasts about 30 s...

Page 164: ...ating offset and the robot sync offset to avoid racing and the risk of a breakdown 1 After checking the system parameters the robot can be started From MOTOR OFF as described in chapter 4 3 the robot system is switched to MOTOR ON by pressing the enabeling device on the programming unit 2 Robot with absolute measurement has a well known absolute position if the robotis calibrated and is therefor d...

Page 165: ...puter board RWM memory with belonging battery back up Observe that when storing system parameters on a floppy disk or host computer is beside the sysemparameters ace to group 1 and 2 also the following system and programdata are stored TCP BASE POINT FRAME ALIGN SENSOR PALET and SOFT SERVO Note that when loading parameters from the PROM memory to the RWM memory values for resolver data parameters ...

Page 166: ...DISK and TO DISK respectively to down load and store sets of parameters between the RWM to a floppy disk RESOLV to check and change the calibration of the resolvers see remark below FR SC and TO SC respectively to down load and store sets of parameters between the RWM and a computer SC or option The main menues under PARAM is only available if 1 Key switch on the control cabinet are in either MANU...

Page 167: ...list of parameters and keywords is included at the end of this chapter see section 5 6 5 1 3 Handling system parameters to or from a diskette Storage to diskette Function Storage of active system parameters from the parameter memory to the diskette First insert a formatted diskette in the disk drive unit The diskette may contain associated program blocks Menu TO DISK from the main menu Note No ini...

Page 168: ...k questions and initialization as described in section 5 1 5 5 1 5 Concluding procedures 1 Every time the user chooses to load parameters from PROM floppy disc or a superior computer the old parameters are copied to a mirror area A check question is displayed if the new RESOLV parameters differs from the old ones as per figure below and then the possibility is given to reload the old RESOLV parame...

Page 169: ...s are unsynchronized if not absolute measurement In robot with external axes without the absolute measurement these must be synchronized after the MOTOR is selected No INTT is performed when ending the PARAM mode with ACTIVE and no changes of the systemparameters has been made the robot then answers by displaying the main menue under MAN When handling system parameters it is a good rule to always ...

Page 170: ...der the menu show in which section the parameter is explained se also next page Basic MH ASM S WELD and GLUE ARC Weld INAJUI AXIS ACTIVE KHUM SC 5 2 4 2 IIMOH MM AUTO CIRCLE CLINK SCA 5 2 4 3 5 2 4 5A 5 2 4 5 GRIPPER LOAD OPTION SC IN OUT AXIS AUIIVt PROM SCA 5 2 4 2 INCH MM AU1O CIRCLE CLINK SCA 5 2 4 3 5 2 4 5A 5 2 4 VOLT CURR LOAD OPTION WIRE SP if wire speed was selected Under PARAM CHANGE the...

Page 171: ...bmenu to OPTION for the robot variants BASIC MH ASM and GLUE 5 2 4 2 5 Submenu to OPTION for the robot variant IRB 2000 ARCW Submenu to AUTO Optimazed running vetocty PATH 1 Submenu to VOLT Arc welding parameter tor IRB 2000 AW Submenu to CURFV WIRE SP Arc welding parameter for IRB 2000 AW 5 2 4 2 4 5 2 4 2 4 INSTALLATION 5 7 S3 ...

Page 172: ...ctions 5 3 have no predefined values and are cleared with this operation Menu PARAM CHANGE PROM Resulting menu System language selection Select the language required Check questions The system concludes with check questions and initialization as described in section 5 1 5 INSTALLATION S3 5 8 ...

Page 173: ...nding or suspended The parameter is used to adapt the control of the servo system to the gravitational conditions which apply in the alternative cases Menu SYNC Guide text MOUNTING Def range 1 Standing robot 2 Suspended robot not IRB 6000 Default value 1 Standing robot Code 1 Standing Suspended INSTALLATION 5 9 S3 ...

Page 174: ...e 0 Servo system axis An with sync switch 1 Absolute measurement servo system axis An according to the method with Fine Coarse resolver Default value 0 Servo system axis An with sync switch Note The system cannot be started if the value of the parameter does not correspond to the robots actual configuration Restart in absolute measurement system Description The parameter RESTART is used to specify...

Page 175: ...For robots with absolute measurement servo system the position is used only for calebration The parameter can be used on standing or suspended robots Menu Resulting question after MEASUREMENT TYPE An or after RESTART Guide text SYNC POS NO Code land 4 90 Code 2 and 5 90 Suspended Code 0 and 3 0 AXIS Code 0 1 2 0 AXJS_2 Code 3 4 5 90 AXIS 2 INSTALLATION S3 5 11 ...

Page 176: ... programming unit monitor display screen and printer for program printout Menu INCH MM Guide text UNIT Def range 0 Si units MM MM S KG 1 American units INCH INCH MIN POUND Default value 0 Si units 5 2 4 4 Zone The zones used at points have different meaning and value depending on which optimizing principle is used speed or path optimizing Path optimizing use a corner zone showing how far ahead of ...

Page 177: ...wo types of zone size definition Absolute value the zone size directly corresponds to the defined size in rectangular coordinates Velocity dependent value the zone size is proportional to the programmed TCP velocity At 1000 mm sec the zone size corresponds to the defined size in rectangular coordinates Definiton of zones The system parameter ZONE is used to define the different available zones COR...

Page 178: ...f the size of the zero zones is performed in mm Programmed position Small zero zone Large zero zone Extra large zero zone Size of zero zone Route of TCP The size of the zero zone expressed in mm is almost in agreement with the actual size under the following conditions only The movement is performed with maximum extended robot arm and with TCP 0 active This means that in most cases a smaller real ...

Page 179: ... each axis is with in a defined zero zone before the next movement begins when positioning to coarse points The coarse point works just as a fine point in cases like this Menu AUTO ZONE COARSE Information text PRESENT VALUE NOT DEFINED No zero zone for coarse points Menu selection DEFINE Define zero zones for coarse points UNDEF Undefine zero zone for coarse points BREAK No change required Paramet...

Page 180: ...th An arc of up to 360 can be obtained from three points 2 CIRCLE POINT 4 CIRCLE POINT 2 CIRCLE POINT 0o 180 180 360 Method A Method B Description Menu Guide text The orientation of the tool in relation to the circle path CIRCLE ORIENTATION TO CIRCLE Def range 0 The orientation of the tool is linear interpolated along the circle path 1 The orientation of the tool is constant in relation to the cir...

Page 181: ... IRB IDENTITY is used to define the identity of the robot in question in a system containing more than one robot connected to a superior computer host computer Guide text Menu Def range IRB IDENTITY Resulting question after DEFINE above Identity 0 127 Default value 0 5 2 4 7 1 I O Type The figure below shows how the optional I O boards can be placed in the rack Always max 6 l O boards I O BOARD PO...

Page 182: ...re not included With definition as panel I O digital inputs 1 8 and digital outputs 1 8 on the board in question in numerical sequence are not included The system simply jumps over the reserved physical inputs and outputs on the board in question with the logical numbering from right to left in such a way that the logical numbering has a consecutive number sequence 1 2 3 etc 2 Logical numbering on...

Page 183: ...X X luarte 2 X X r 3 X Se chapter 5 2 4 28 5 2 4 31 for more information of RIO board DSQC 239 5 2 4 7 2 DIGITAL INPUT and OUTPUT Description Menu for selection of physical input logical input and output ROBOT DIG I O Menu DIG INPUT or DIG OUTPUT Information text PHYS INPUT INP If already defined PHYS INP 01 01 INP 1 SYS OUTPUT SYS A system or panel input is defined OUTP An output is linked for th...

Page 184: ...AMP FROM DISC ERROR LAMP SYNC FROM DISC PROG START SYNC LAMP PROG STOP PROG START LAMP KEY SWITCH EMERGENCY STOP LAMP LAMPTEST PROG STOP LAMP If an input output is already defined it will be shown like HOLD 0112 were 01 is the board position and 12 is the channel number in this example ENTER without value will not change anything 5 2 4 7 4 LINK I O Description Menu to define physical inputs to be ...

Page 185: ...inter connected BREAK no change required Parameter If a printer is connected to the control system the parameter BAUD RATE is used to determine the data transmission speed for printer printout Guide text BAUD RATE Def range 300 Transmission speed 300 Baud bit second 1200 Transmission speed 1200 Baud Default value 300 Transmission speed 300 Baud 5 2 4 9 MONITOR display screen Description The parame...

Page 186: ...to define the board position where digital inputs 9 16 and digital outputs 9 16 are reserved as system I O Menu The resulting question after DEFINE above Guide text BOARD POSITION Def range 1 6 corresponding to board place 1 6 Note It is recommended to reserve system I O on the last I O board and to define the same I O board for panel I O board for panel I O if used Default value No board place is...

Page 187: ...be reserved for use as panel I O Menu IN OUT I O USE PANEL Information text PRESENT VALUE NOT DEFINED Panel I O not reserved PRESENT VALUE DEFINED Panel I O reserved Default value Panel I O not reserved Menu selection DEFINE Reserve panel I O UNDEF No panel I O reserved BREAK No change required Parameter If panel I O is reserved the parameter BOARD POSITION is used to define which board position 1...

Page 188: ...which the axis can be run in positive or negative directions from the normal calibration position synchronization postion Menu AXIS ROBOT Guide text Al Negative direction axis 1 s A6 A6 Positive direction axis 6 Def range 1 The angle is to be specified in whole degrees and with sign 2 Max and min value for the parameters Al to A6 must be within the working range marked in the figure below Default ...

Page 189: ...IRB 2000 IRB 3000 IRB 3200 IRB 6000 IRB 6000 S3 0 100 A2 IRB 2000 IRB 6000 IRB 6000 S3 0 100 Axis 3 limits A3 IRB 2000 IRB 3000 IRB 3200 IRB 6000 IRB 6000 S3 0 100 A3 IRB 2000 IRB 3000 100 90 90 70 140 110 JJQ 110 70 10 160 150 150 105 155 170 170 IRB 6000 S3 0 100 52 Value include axis 2 INSTALLATION 5 25 ...

Page 190: ...here as an external axis has an external drive unit If axis 7 is defined as internal then independent movement of this axis is not permitted AW Any axes can be defined as internal up to 6 axes can be defined only one can be active See STATION chapter 5 2 4 15 External axes with external drive units demands that aaxis board DSQC 233 is placed at board position in rack see fig in chapter 3 10 For ex...

Page 191: ...ired Working area axes 7 12 Description Menu selection to define whether or not the axis in question has defined working area Normally is a working range definined for external axes For rotating axes that are used as external axis the parameter be undefinined Menu AXIS EXTAX AX or AXIS AXIS 7 X in AX is the number of the axis in question Info text PRESENT VALUE DEFINED The axis in question has a w...

Page 192: ...ization position Menu Resulting question from DEFINE above Guide text AX Working range negative direction AX Working range positive direction X is the number of the axis in question Def range Max numerical value of motor increments entered 2147483640 Min numerical value of motor increments 0 The numerical value must be given with a sign minus sign for axis AX and no sign for AX INSTALLATION 5 28 ...

Page 193: ...0 0 127 0 in Si unit Per second 1 s Default value The gain is undefined Note 1 Values of the gain which can be used in practice are of the order of 5 for high inertia to 20 for low inertia mechanical units 2 With ENTER without data and undefined gain the sequence cannot be left and the system restarts with parameter III Motor speed axes 7 12 Parameter IV The parameter MSPEED RPM gives the maximum ...

Page 194: ... external drive unit One additional optional a c motor can be controlled by the control system in addition to the 6 robot axes The a c control is activated by selecting axis 7 as an internal axis This can be used for example for a travel motion Even when defining the axes 8 12 the question whether the axis is to be internal comes up Menu Resulting question after reading in in accordance with 5 2 4...

Page 195: ... control from internal drive unit Guide text P GAIN TIMES Def range 0 0 127 0 times Default value 17 times for IRB 2000 Track Motion 16 times for IRB 3000 Track Motion 17 times for IRB 6000 Track Motion Note Values practically usable approx 5 for low inertia to 25 for high inertia mechanical units Parameter VIII Internal drive unit axis 7 Integration time I part Menu Resulting question according t...

Page 196: ...xis 7 Menu Resulting question of drive unit for the internal axis 7 Guidtext DRIVE UNIT Selected type of drive unit from the meny Default value IRB 6000 T Drive unit IRB 2000 3000 C Drive unit Type of motion axes 7 12 Description Menu selection to define if an independent external axis controls a linear movement or a rotating movement Menu Resulting question from definition of external axis with e...

Page 197: ... speed reference to the motor for the external axis concerned should correspond to the specified maximum speed Menu Final question for axes 7 12 with external drive unit Guide text MSREF V Def range 0 0 9 4 V NOTE The speed reference voltage has a 12 bit resolution With a specified 9 4 Voltage level a disturbance on the least significant bit will result in a fluctuation in the speed reference The ...

Page 198: ... BRAKE CONTROL connected to external axes with brakes is activated This signal must also be used to block the servo of the external axes to prevent the speed controller from integrating up to the current limit To avoid dipping when brakes are applied a time delay relay should be used on the signal to block the servo 5 2 4 15 STATION AW only Sharing of external axes on stations Description The para...

Page 199: ...mber 0 is presented a value must be specified AXES The external axes which are to belong to the station in question are specified here Menu Continued question after DEF above Guide text AXIS No Permitted values The external axes 7 8 9 10 11 and 12 are permitted Note The request for the axis number is repeated until answered without specification of an axis number When the request for the first axi...

Page 200: ...tion is to be synchronized separately from other asterisk marked stations Note The asterisk marked stations are synchronized in a sequence beginning from the last and the first is synchronized together with those not marked After the synchronization all of the stations are deactivated except A An axis can not belong to more than one station INSTALLATION S3 5 36 ...

Page 201: ...rippers Default value 2 grippers Parameter II The parameter specifies the logical digital output which gripper 3 is to be connected to Menu Resulting question Info text PRESENT VALUE Guide text OUTPUT NO GRIPPER 3 Def range Logical digital output 1 128 Default value Logical digital output 9 Note When 4 8 grippers are specified under Parameter I above the control system will automatically reserve t...

Page 202: ...al masses the position and sizes of the joint centre of gravity must be calculated Center of gravity of mounted equipment Pivot point Xmm Parameter I The parameter indicates the weight of the equipment concerned Menu LOAD Guide text MASS Def range Default value Permitted values ARM KG IRB2000 0 15 kg 1KB 2000 Okg IRB2000 0 5 kg IR63000 0 15 kg 1KB 3000 Okg IRB3000 0 15 kg IRB3200 0 15 kg IRB3200 O...

Page 203: ...used in reading in and reading out 1 inch 25 4 mm See the manual Description concerning permitted position of extra load Parameter III The parameter specifies the distance from the centre joint between the lower arm and the upper arm to the centre of gravity of the equipment perpendicular to the upper arm shown as Z in the figure above Menu Resulting and final question Guide text Z MM Def range IR...

Page 204: ...ht and the position of its centre of gravity In other words the nature of the normal load Center of gravity of the load Xmm Parameter I The parameter specifies the weight of the load Menu LOAD WRIST Guide text MASS KG Def rangeIRB 20001KB 3000 0 10 kg 0 30 kg Default value IRB 2000 IRB 3000 10 kg 30 kg IRB 3200 0 10 kg IRB 3200 10 kg IRB 6000 2 4 120 2 4 150 2 8 100PT 3 0 75 S3 0 100 2 25 PE 75 IR...

Page 205: ...tion Control Hold to run Active parameter 1 means that in theone off the following function buttons must be kept depressed for execution When the buttons is released the robot stops PROGST INST BWD ALIGN MH GIVSW SYNC EXTALIGN AW VARNING Hold to run should always be active to avord injury If not active the robot does not stop at release of above buttons Menu Info text SAFETY HOLD RC PRESENT VALUE ...

Page 206: ... on the outputs 1 Outputs will be reset at emergency stop Default value 0 Warning If the parameter DIG OUTPUT RESET is set to 1 It is very important that the peripheral equipment is adapted to that all outputs are reset at emergency stop and automatically restored to its former condition when the emergency stop is reset 5 2 4 19B AUTOK AUTO control Under this menufunctions in AUTO mode can be bloc...

Page 207: ...n AUTO mode UNBLOCKED The function can be performed in AUTO mode Default value UNBLOCKED 5J2 4 19B 2 HAND Description The HAND parameter exists for blocking of manual functions under the MANUAL button in AUTO mode In MANUAL mode HAND operates as previously irrespective of whether blocking has taken place Menu SAFETY SCAN AUTOK HAND Info text FUNCTION IN AUTO Definition range BLOCKED The function c...

Page 208: ...AL mode the ORIDE function as previously operates irrespective of whether blocking has taken place Menu SAFETY SCAN AUTOK ORIDE Info text FUNCTION IN AUTO Definition range BLOCKED The function cannot be performed in AUTO mode UNBLOCKED The function can be performed in AUTO mode Basic state BLOCKED 5 2 4 19B 5 SPEED Description The SPEED parameter under the AUTOK menu exists for blocking of the SPE...

Page 209: ...L in automatic operating mode In manual operating mode the RESET function operates as previously irrespective of whether blocking has taken place Menu SAFETY SCAN AUTOK RESET Info text FUNCTION IN AUTO Definition range BLOCKED The function cannot be performed in AUTO mode UNBLOCKED The function can be performed in AUTO mode Basic state UNBLOCKED 5 2 4 19B 8 PROGST Description The PROG ST parameter...

Page 210: ...he BWD function operates as previously irrespective of whether blocking has taken place Menu SAFETY SCAN AUTOK BWD Info text FUNCTION IN AUTO Definition range BLOCKED The function cannot be performed in AUTO mode UNBLOCKED The function can be performed in AUTO mode Basic state UNBLOCKED 5 2 4 19B 11 DISPL Description The DISPL parameter exists for blocking of the DISPL function under AUTO in AUTO ...

Page 211: ...ED 5 2 4 19B 13 SIM Description The SIM parameter exists for blocking of the SIM function under AUTO in AUTO mode and in program running In MANUAL mode the SIM function operates as previously irrespective of whether blocking has taken place Menu SAFETY SCAN AUTOK SIM Info text FUNCTION IN AUTO Definition range BLOCKED The function cannot be performed in AUTO mode UNBLOCKED The function can be perf...

Page 212: ...ent caused by an active reference point is not added to the position def 1 Menu AUTO RP MODE Guide text REFERENCE POINT MODE Def range 0 Storage of current robot position compensated for parallel displacement caused by an active reference point 1 Storage of current robot position only Default value 0 storage of parallel displaced robot position if reference point is activated 5 2 4 23 AW REST Desc...

Page 213: ...efinition from PROM It is recommended to use path optimized running if nothing else is required Normal corner zones will be installed when path optimizing is installed The motion will be stopped when changing from ROBOT toRECT coordinates 1 Velocity optimized running Velocity optimized running gives a smoother velocity at the cost of the path quality The robot will have the same path performance a...

Page 214: ...The definition range for the combined I O is from 0 to 10V The principle of the conversion in the control system of programmed welding current to current reference in the form of reference voltage in volts is given by the following curve Currant reference Reference voltage at output port Refmax V Ref min V V Straight line which controls the conversion Programmed welding current A Points to type an...

Page 215: ... The parameter PARAM MAX V defines maximum welding voltage Menu Resulting question Guide text PARAM MAX V Def range 30 0 100 0 V Default value 100 V Parameter III The parameter REF MIN V defines the minimum voltage reference reference voltage in V Menu Resulting question Guide text REFMIN V Def range 10 0 to 10 0 V Default value 0V Parameter IV The parameter REF MAX V defines the maximum reference...

Page 216: ...rence Description The parameter CURRENT PORT defines which output port is to be used as current reference Menu CURR PORT Guide text CURRENT PORT Def range Port 21 23 Combined I Port 21 22 Default value Port 22 Note Port 24 can be defined but the system then issues 20 mA instead of 10 V Not valid for the combined I O Control of current reference Parameter I The parameter PARAM MIN A defines the min...

Page 217: ... permissible conversion curve with the parameter values this sequence can not be concluded and the system will request parameter I again This can happen if the values entered lie outside the permitted values or if the minimum value entered is higher than the maximum value entered The sequence can always be concluded by entering the default values Port for wire speed reference Description The param...

Page 218: ... The parameter PARAM MAX M MIN defines the maximum wire speed Menu Resulting question Guide text PARAM MAX M MIN Def range 0 0 50 0 m min 0 1968 inch min Default value 50 0 m min Parameter III The parameter REF MIN V defines the minimum wire speed reference Menu Resulting question Guide text REFMIN V Def range 10 0 10 0 V Default value 0V Parameter IV The parameter REF MAX V defines the maximum wi...

Page 219: ...numbering during editing is permitted Renumbering is not permitted when the parameter is set to the value 0 If an attempt is then made to use the function the following error message is presented NOT ALLOWED COMMAND Menu OPTION RESEQ Info text PRESENT VALUE 1 Guide text RESEQUENCE ALLOWED Def range 0 Renumbering during editing not allowed 1 Renumbering during editing allowed Default value 1 5 2 4 ...

Page 220: ...troller is performed via a standard I O DSQC 223 Default value 0 Menu Resulting question after SWI 1 Guide text Board position Def range The I O board can be placed in a optional position and receives I O number in the ordinary way The standard function with sub programs for control of the welding controller can be used even when the parameter SWI is activated 5 2 4 28 RADR rack address RIO board ...

Page 221: ...5 26 27 28 29 30 31 RACK ADDRESS AB SERIES 3 OR 5 40 41 42 43 44 45 46 47 50 51 52 53 54 55 56 57 60 61 62 63 64 65 66 67 70 71 72 73 7 75 76 77 ABB ROBOT 32 33 34 35 36 37 38 39 40 41 49 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 5 2 4 29 STQUART starting quarter RIO board Description The parameter starting quarter states which starting quarter the address is within Menu STQUA...

Page 222: ... 5 2 4 31 DRATE data rate RIO board Description The data rate between the RIO board and the PLC equipment must correspond with the one that is set for the PLC computer Menu DRATE Guide text DATA RATE Def range 0 1 or 2 0 57 6kbits s 1 115 2 kbits s 2 230 4 kbita s Defaultvalue 0 5 2 4 32 ROTAX MH GL SW Description Active parameter 1 means that an external axis if it is defined as rotational can be...

Page 223: ...sist of commutation and synchronizationoffsets for the different axes which are both determined by the angular position of the resolver under certain specific conditions The resolver data must NEVER changed without the external and internal axes of the robot system fulfilling these certain specific conditions See service manual It is not possible to change commutationoffset data for IRB 6000 The r...

Page 224: ...ttempted when the robot is in the MOTOR ON mode For IRB 2000 motortypes are defined ace to table below Motor type 1 2 3 Article number IRB2OO0 4429 548 BX 4429 548 BW 4429 584 Bl 1 3 2 1 3 Axis ELMO ELMO Siemens If an attempt is made to take the robot into MOTOR ON without motortype defined the following error message will be displayed 542 MOTORTYPE NOT DEFINED and the robot will remain in MOTOR O...

Page 225: ...on of the fine resolver in resolver increments Active commutation offset in resolver increments obtained from the parameter memory Sub menu for calibration offset Sub menu to SYNCOFF HtSOLVbH Al UUUNI hH In the case when external axes are defined with absolute measurement servo system according to the method with fine coarse resolver is also this alternative available RESOLVER A1 COARSE INSTALLATI...

Page 226: ...menu in which UPDATE can be executed the actual position of the resolver FINE XXXX or COARSE YYYY is presented the form of a mean value of all samples 2 times sec Before selecting UPDATE it is advised to wait for approx 1 5 s after having run the robot When UPDATE is pressed the actual mean value of the resolver position is transferred to the parameter memory 3 The function MAN DEF a Method A An a...

Page 227: ... axis 7 is 2048 adjusted for certain factory commutated motors 3 The values which apply for the robot installation are always specified in the robot ID document It is therefore important to define the resolver parameters after loading the predefined parameters from the PROM Menu selection UPDATE The actual position of the resolver is transmitted by the control system to the parameter memory This a...

Page 228: ...parameters must therefore be entered after such an operation The values which apply for the robot installation are always specified in the robot ID document except for the counter that always is updated manually Menu selection UPDATE The actual position of the resolver is transmitted by the control system to the parameter memory This assumes a rotor position in accordance with the definition above...

Page 229: ... is presented on the display Before pressing the synchronization button make sure that external axes are free to move into the synchronizing position home position Test running should be performed in a series of steps Begin by running the robot manually through its complete working range A simple positioning program can then be test run instruction by instruction to begin with and then in an autom...

Page 230: ...lable 501 ERROR IN PARAMETER MEMORY RELOAD FR DISK FR PROM a Loading of predefined parameters from the PROM Press FR PROM Note that not all the system parameters are predefined That means that when reloading the resolver and commutations offsets will be reset b Loading of stored parameters from diskette Insert a diskette containing valid system parameters in the disk drive Press FR DISK Check that...

Page 231: ...line and a menu for selection of changes of the parameter memory on the lower line First correct any incorrect equipment settings 513 MISPLACED I O BOARD Then select a suitable alternative to correct any incorrectly defined system parameters a Individual system parameters can be corrected with CHANGE See further section 5 2 Select ACTIVE in the succeeding menu to start up the system after the inco...

Page 232: ...AIN PORT PRINTER PROM REFMAX REFMIN REF POINT RESEQ RESOLV RESTART ROBOT INSTALLATION Section 5 2 4 13 5 2 4 2 5 1 2 5 2 4 17 5 2 1 5 2 4 13 5 2 4 23 5 2 4 14 5 2 4 4 5 2 5 2 4 5A 5 2 4 5 5 3 4 5 2 4 4 5 2 1 5 2 4 24 5 2 1 5 2 4 23B 5 2 4 7 2 5 1 3 5 2 4 19A 5 5 5 2 4 10 A 5 2 4 13 5 2 4 15 5 2 4 4 5 1 3 5 1 4 5 2 4 20 5 2 4 16 5 2 4 19 5 2 4 7 1 5 2 4 3 5 2 4 5 5 2 4 13 5 2 4 13 5 2 4 7 4 5 2 1 5...

Page 233: ...m I O SYSTEM or PANEL I O TO DISK TOSC VOLT WIRESP Working range ROBOT WRIST ZONES 5 2 4 22 5 2 4 19B 5 1 4 5 2 4 15 5 2 4 26 5 2 4 27 5 2 4 2 5 3 2 5 5 2 4 2 5 2 4 10 5 2 4 7 3 5 1 3 5 1 4 5 2 1 5 2 4 24 5 2 1 5 2 4 24 5 2 4 12 5 2 4 18 5 2 4 4 INSTALLATION S3 5 69 ...

Page 234: ...INSTALLATION 5 70 ...

Page 235: ...between an internal and an external 7th axis Max no of external axes Drive unit Motor internal axis 7 4 IRB 2000 3000 0 IRB 6000 AC drive in control cabinet 4 or 6 pole synchronous motor of IRB type external axis 7 6 IRB 2000 3000 1 IRB 6000 External drive unit with speed reference from control system DC or AC depending on drive unit Connection for monitoring motor temperature Yes No If an interna...

Page 236: ...nals from the robot for MOTOR ON MOTOR OFF applying brakes For internal drive unit A 4 or 6 pole AC synchronous motor type IRB For systems without absolute measurement One resolver per axis for position control One sync switch per axis for definition of sync position For systems with absolute measurement Two resolvers per axis for position control and absolute measurement One resolver and serial m...

Page 237: ...hes Max voltage Load Motor Internal axis 7 Technical data drive units Rotor 2 kHz 5 6 Vrms 150 ohm 0 5 A rms 12 resolvers Stator 0 5 10 200 ohm 1 1 136 137 35VDC min 10 mA ABB Production Development have further information Resolver for serial measurement board Electrical data Primary Rotor Frequency 3 4 kHz Rated voltage 5 Vrms Impedance 350 ohm Secondary Transmission ratio Impedancex Phase shift...

Page 238: ...throughout the system All limit switches are connected in series An open circuit indicates that the external axis has reached the limit of its working range and this will tripthe safety chains in the robot The signal must be jumpered if not used When the MOTOR ON button in the control system is kept depressed the axis can be jogged past the limit position switches back into working range Note The ...

Page 239: ...wing Supply of sync switches and associated control function external axes without absolute measurement Supply of external brakes X FINE 7 12 Y FINE 7 12 X COARSE 7 12 Y COARSE 7 12 O V The X FINE Y FINE and 0 V signals are used for connecting fine resolvers to the control system The X COARSE Y COARSE and 0 V signals are used for connecting coarse resolvers the external axes are provided with abso...

Page 240: ...abling Connection in noisey environment internal 24V supply Control system 24 y J Q OVI O OVSYNC SYNC See 6 3 3 Connection table external axis Sync switch Screened cabling Connection in noisey environment external 24V supply Control system See 6 3 3 Connection table external axis OVSYNC SYNC External 24 V OV Sync switch Screened cabling INSTALLATION 6 6 ...

Page 241: ... contains two stators and one rotor connected as shown in the figure below Control system EXC OV X FINE COARSE OV See 6 3 3 Connection table external axis Y FINE COARSE 6 3 2 Internal Internal axis 7 is connected according to below M17 M27 M37 Motor current R phase U phase S phase V phase and T phase W phase respectively Control system M17 M27 M37 PTCM7B 0 V PTC M7B A1 B1 C1 XS7 A2 B2 rC2 D2 ni R ...

Page 242: ...e units EXT MON 1A 1B and 2A 2B Orders MOTOR ON MOTOR OFF status in the control system to the common logic for external axes Closed loop indicates that the control system is in MOTOR ON mode voltage to motors Open loop indicates MOTOR OFF mode no motor voltage EXT BRAKE ON Orders BRAKE ON BRAKE OFF from control system Closed loop indicates that the robot brakes are not engaged i e the motors retai...

Page 243: ... to the current limit when the brakes are activated To prevent an external axis equipped with brake from moving when the brake is operated applicable to axes affected by gravitation an extra time delay may be created between EXT BRAKE ON and BLOCK as follows EXT BRAKE ON Rl OOK VREF 7 12 0 V VREF 7 12 Analog reference signal 10 10 V for the speed reference from control system to the external drive...

Page 244: ...tion table external axis 7 User contact XS4 EXC C6 OVEXC D6 XFINE C8 YFINE D8 OVFINE B9 OVREF B3 VREF A3 SYNC Al OVSYNC C2 X COARSE A8 Y COARSE B8 OV COARSE A9 Connection table external axis 8 User contact A26 X2 1 eiler B1 X5 1 EXC C6 OVEXC D6 XFINE CIO YFINE D10 OVFINE D9 OVREF D3 VREF C3 A11 B12 and Bll B12 jumpered if not used C12 A15 jumpered if not used SYNC OVSYNC XCOARSE YCOARSE OV COARSE ...

Page 245: ...0 EXC OVEXC XFINE YFINE OVF OVREF VREF SYNC OVSYNC XCOARSE YCOARSE OV COARSE C6 D6 Cll Dll B12 64 A4 Cl C2 All Bll A12 C7 D7 C13 D13 D12 D4 C4 Dl C2 A13 B13 C12 Connection table external axis 11 EXC C17 OVEXC D7 XFINE C14 YFINE D14 OVFINE B15 OVREF B5 VREF A5 SYNC A2 OVSYNC C2 X COARSE A14 Y COARSE B14 OV COARSE A15 INSTALLATION S3 6 11 ...

Page 246: ...Connection table external axis 12 EXC OV XFINE YFINE OVFINE OVREF VREF SYNC OVSYNC XCOARSE YCOARSE OV COARSE C7 D7 C16 D16 D15 D5 C5 B2 C2 A16 B16 C15 INSTALLATION S3 6 12 ...

Page 247: ... or brake if there is one and the motor shaft coincide Bead note and update the resolver position preliminary commutating offset see section 5 3 4 For certain types of motors with built in resolver the commutation offset is predefined to the value 2048 1 these cases there is no need of changing the commutation offset Check that right commutation offset is defined Wrong value can result in an uncon...

Page 248: ...n increases again If the value decreases change polarity on one stator winding of the fine resolver signals Y FINE and X FINE and repeat 4 Press the enabeling device to get MOTOR ON mode If any of the external axes races or if a servo lag fault is obtained on the programming unit the following faults may have occurred Wrong polarity on tachometer feedback connection Wrong polarity on speed referen...

Page 249: ...a 2 Connect the printer channels to the test outputs on the robot computer Marked 1 and 2 with common zero point ground Voltage level 10 V 3 TSIG Activate test signals via the P unit using function TSIG see section 6 5 4 1 CHANNEL 0 output 1 TEST SIGNAL 17 speed high or 18 speed low CHANNEL 1 TEST SIGNAL 16 torque reference 4 TRIM TUNE The TUNE function is not yet available The tuning parameters a...

Page 250: ...deal step control response speed control 6 5 3 Position control 1 If the axis has variable moment of inertia the gain should be trimmed with maximum moment of inertia 2 Connect one channel of the printer chart recorder to test output on the robot computer test output 2 with common zero point ground Voltage level 10 V Connect the other channel of the printer to the tachometer signal of the axis bei...

Page 251: ...e that max speed is reached before declaration starts WATTING TIME 2 s the time chosen should be sufficient to allow the axis to stop before turning 6 TRIM START Start the defined movement by pressing the START button 7 TRIM TUNE Adjust the gain in the following manner Increase the gain EL using system parameters steps of 0 5 until the quickest deceleration is obtained without overshoot Speed Time...

Page 252: ...ENT VALUE X Q SIGNAL NO 16 17 or 18 CE E 1 PRESENT VALUE AXIS NO 7 12 D uM x CE ENTERp Axis Internal axis i IRB2000 3000 Track motion Internal axis 7 IRB6000 Track motion Torque reference Test signal 16 AN 1 32 5 2 AeWV 0 93 3 68 Nm V 1 82 3 05 Kt Nm Aeff 1 95 0 83 Speed Test signal 17 rpm V 222 522 Test signal 18 rpm V 13 8 32 6 Fig The scale of testsignals INSTALLATION S3 6 18 ...

Page 253: ...ed out the system has to be initialized again If the system is provided with external axes with relative measurement the system has to be resynchronized before program running MAN SCAN SCAN SCAN SCAN TRIM READSYN TSIG TUNE is used when new control parameters are to be entered see below START is used to start the trimming movement MOVE is used to define the trimming movement see below PRESENT VALUE...

Page 254: ...POSGAIN SPEED D D w w T O w v f vw v re m w If axis 7 is an external axis an error printout will be given and a return to the above hierarchy will result INSTALLATION 6 20 S3 ...

Page 255: ...VALUE X 1 100 of max velocity number of motor turns w nr w T o mJ Ma a33n 1 v wm m W J I PRESENT VALUE X CE ENTER M3m 0 131 0 Type 1 axis movement in positive direction Type 2 axis movement in negative direction Type 3 5 speed regulated cycles positive movement wait negative movement wait etc Type 4 5 position regulated cycles positive movement wait negative movement wait etc INSTALLATION 6 21 ...

Page 256: ...solver position while in the synchronizing position Note it down and update the resolver offset see section 5 3 5 The resolver reading in the synchronizing position is the correct value for the synchronizing offset 5 Repeat the above procedure for all external axes 6 Start the system synchronize and check synchronization positions Adjusting absolute measurement 1 Define the external axes as absolu...

Page 257: ... start up and Parameter index This chapter contains start up procedures from previous chapters 7 1 Check list before start up 7 2 Start up to standby 7 3 Test running 7 4 Coupling diagrams INSTALLATION S3 7 1 ...

Page 258: ...F clamping device XS3 or XT3 External axes limit switches XS3 or XT3 Ext drive units POWER OK XS3 or XT3 A3 A4andB3 B4 Al A2 and Bl B2 A5 A6 and B5 B6 A7 A8 and B7 B8 A9 A10 and B9 B10 Cl C2 and Dl D2 All A12andBll Bl2 C12 C16 4 If the controller includes the external axes option check that the external axes connections are made or the following circuits are jumpered Motor PTC axis 7 XS7 7th 12th ...

Page 259: ...t message 501 FAULT IN THE PARAMETER MEMORY RELOAD is displayed must the system parameters must from DISC be entered ace to chap 5 5 Parameter error The system floppy disc delivered with the system is used This disc contains system parameters with resolver data that was valid at delivery of the robot system according to chapter 8 D Specific system parameters Define the specific system parameters t...

Page 260: ...for operation the MOTOR ON lamp will start to flash The external axes are synchronized by pressing the SYNC button on the programming unit 3 The robot is ready for operation when the MOTOR ON lamp stops flashing and the text READY is presented on the display Before pressing the synchronization button make sure that external axes are free to move into the synchronizing position home position Test r...

Page 261: ...OLD1A MOFF HOLD IB EXT MODE COM1 EXTAUTO 1 EXTMAN1 EXTMANFS1 HOLD1 HOLD 11 HOLD 12 EXT BRAKE A EXT BRAKE B POWER OK EJANSLUTEN OV OV 24VI O D MOFFHOLD2 OV EXT MODE COM2 EXT AUTO 2 EXTMAN2 EXTMANFS2 HOLD 2 HOLD 21 HOLD 22 SENSOR 1 SENSOR 2 SENSOR 3 OV SENSOR OV OV OV XS3 D C B A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 External connector XT3 D C B A 10 1U O Screw terminal Note Signal identity corresp...

Page 262: ...INSTALLATION S3 7 6 ...

Page 263: ... at delivery date are stored on the system disk 8 2 Error codes in plain language The function ERROR CODES in plain language provides more information to the operator in case of system errors These are shown on the optional monitor or on the programming unit when the buttons is pressed The texts are stored as ordinary comment instructions and should be loaded into their designated memory area at r...

Page 264: ... code for some of the error messages e g 506 SERVO ERROR 2 1403 If the plain language text ends with AXIS 1 the axis number replaces the 1 In case of resolver errors the fine or coarse resolver is indicated by stating 1 12 for the fine resolver and 13 24 for the coarse If the plain language text ends with AXIS 2 the axis number replaces the 2 After 2 an additional text FINE for 1 12 and COARSE for...

Page 265: ...ting text via instruction numbers In the Error code table the instruction numbers to be used for specific error codes are given 504 PROGRAM RUN ERROR is missing since the error code in this case is calculated according to Instr no 10 error code The table is scanned from the top and downwards and the first hit represents the wanted instruction number When scanning the numbers marked with an F are n...

Page 266: ... calibration position 0 3200 for IRB 3200 calibration position 1 3200 for IRB 3200 calibration position 2 3200 for IRB 3200 calibration position 3 3200 for IRB 3200 calibration position 4 3200 for IRB 3200 calibration position 5 6000 for IRB 6000 2 4 100 calib pos 0 6001 for IRB 6000 2 4 100 1 6002 for IRB 6000 2 4 100 2 6100 for IRB 6000 2 4 150 0 6101 for IRB 6000 2 4 150 1 6102 for IRB 6000 2 4...

Page 267: ...26 0003 3330 26 0004 3340 26 0005 3350 26 0006 3360 26 0007 3320 26 0008 3380 27 FFFF 3500 30 FFFF 7130 1 NOT ALLOWED COMMAND 10 1 NOT ALLOWED COMMAND 3 DATA ERROR 4 INSTR NOT FOUND 5 PROGRAM MISSING 6 MEMORY FILLED UP 7 PROGRAM END 8 PROGRAM NUMBER OCCUPIED 9 INSTRUCTION NUMBER OVERFLOW 10 ADAPTIVITY ERROR 1 10 ADAPTIVITY ERROR 2 10 ADAPTIVITY ERROR 3 10 ADAPTIVITY ERROR 4 10 ADAPTIVITY ERROR 6 1...

Page 268: ...1FF 5050 506 70FF 5050 506 80FF 5050 506 9000 5310 507 0001 5400 507 0002 5410 508 0006 5460 508 000F 5440 508 0010 5470 508 0020 5500 508 0021 5510 508 0022 5530 508 0024 5530 508 0026 5560 508 0027 5570 508 0028 5580 508 0029 5590 508 0030 5600 508 0031 5610 508 0032 5620 509 0000 5800 509 0016 5760 509 0017 5770 509 1029 3230 509 10FF 3260 FINE Tillaggstexter till 506 COARSE 11FF 12FF 2OFF och ...

Page 269: ...SYNC SYNC SYNC SYNC ERROR ERROR ERROR ERROR ERROR ERROR ERROR ERROR 510 SYSTEM ERROR 510 SYSTEM ERROR 510 SYSTEM ERROR 510 SYSTEM ERROR llxx 14xx 15xx 20xx 21xx 22xx 23xx 3 4 5 6 513 514 514 514 514 514 514 514 514 WRONGLY PLACED I O BOARD XXX COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ERROR COMMUNICATION ER...

Page 270: ... W 547 FFFF 6770 547 HYDRAULIC PRESSURE ERROR DC W 548 FFFF 6780 548 ENABLE TWO CHAIN FAULT DC W 550 0001 6810 550 WELD ERROR 1 DC W 550 0002 6820 550 WELD ERROR 2 DC W 551 FFFF 6830 551 WELD ERROR TIMER DC W 552 FFFF 6840 552 WELD ERROR CURRENT DC W 553 FFFF 6850 553 WELD ERROR FLOW DC W 554 FFFF 6860 554 WELD ERROR TEMP DC W 555 FFFF 6870 555 WELD ERROR ENABLE MOVE DC W 567 FFFF 4470 567 ERROR S...

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