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Design and planning

System Description Service Robotics Modules
1004870-EN-05

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CANopen

STO

24 V DC

Inputs

Outputs

24 V DC

Switch

Ethernet

(Modbus/TCP)

STO

STO_

Programmable safety system

PSS 4000

user program

Motion control

user program

Motion controller

(CANopen Master)

End-effector

Indicator lamp

Status

Teach pendant

Voltage supply (230 V AC)

Low voltage power supply

Safety gate
with guard locking

Emergency stop

Enable pushbutton

Robot arm

Stop of all axes
of the robot arm

Demand for a
brake test

Result of the
brake test

Protective stop

Emergency stop

Reset (ST)

Industrial robot

Switch

(Ethernet)

Fig.: Building a standard-compliant industrial robot system with service robotics modules from Pilz

Summary of Contents for PRBT 6

Page 1: ...Service Robotics Modules System Description 1004870 EN 05 Robotics...

Page 2: ...nta tion will be gratefully received Source code from third party manufacturers or open source software has been used for some components The relevant licence information is available on the Internet...

Page 3: ...ve stop external 27 4 5 Protective stop function for PSENmlock safety gate function 29 4 6 Safe retention with holding brakes 31 4 7 Enabling function 32 4 8 Brake test function 36 4 8 1 Brake test fu...

Page 4: ...ation 84 6 1 Setting up the robot control module control cabinet 84 6 2 Setting up and installing the robot arm 84 6 3 Installing the wall holder for the teach pendant 84 7 Interfaces 85 7 1 Bridging...

Page 5: ...13 Order reference 115 13 1 Product 115 13 2 Accessories 116 14 Appendix 118 14 1 Hash value for integrity check of a download 118 14 1 1 Calculate hash value with the command line tool Certutil 119 1...

Page 6: ...perators and system or plant integrators of industrial robots and or industrial robot systems This operating manual is not for guidance in the operation of an industrial robot and or in dustrial robot...

Page 7: ...us situation that could lead to serious injury and death and indicates preventive measures that can be taken CAUTION This refers to a hazard that can lead to a less serious or minor injury plus materi...

Page 8: ...ency stop signal Enabling signal STO CANopen 24 VDC 24 VDC Robot arm End effector X1 Power 4 5 7 X3 AUX 6 X2 Signals 230 VAC Fig Industrial robots with service robotics modules from Pilz Legend 1 Robo...

Page 9: ...nterface Ethernet for transmitting the robot program from the teach pendant to the motion controller Low voltage power supply 24 V DC Control cabinet main switch 4 Connection cable to X3 AUX of the ro...

Page 10: ...he standards in accordance with EN ISO 10218 1 1 2 3 4 5 6 7 Fig Design and components of the robot arm Legend 1 Base of the robot arm For mounting of the robot arm on a suitable surface With connecti...

Page 11: ...to allow robot movement in the manual operating modes Control button to move the axes of the robot arm in the manual operating modes only in combination with the enabling device The following operati...

Page 12: ...he drives is present ERR Fault diagnostics The LED will light up red when diagnostic messages from the safety control system and or the motion controller are present 2 Key switch with two switch setti...

Page 13: ...obotics Modules 1004870 EN 05 13 2 1 3b 3a Fig Rear view of the teach pendant Legend 1 Control buttons for moving the axes of the robot arm only for manual operating modes 2 Handle and device bracket...

Page 14: ...Motion controller from Pilz including Pre installed motion control user program Communication interface CANopen for controlling the axes and the end effector Communication interface Ethernet for tran...

Page 15: ...CM1 control cabinet is used as a component to operate the industrial robot in compliance with the standards in accordance with EN ISO 10218 1 The robot control module PRCM1 control cabinet is construc...

Page 16: ...y guidelines in the operating manuals for the relevant products Please also read the information in the Operating manual for the robot arm PRBT 6 Operating manual and online help for the teach pendant...

Page 17: ...ls for the robot arm must be adhered to The robot arm is a vertical axis or more specifically a gravity loaded axis The following requirements for the plant or machine design must be adhered to The ro...

Page 18: ...eas with increased environmental requirements e g potentially explosive areas The following is an example of misuse or abuse and is not permitted Use for the transport of people or animals Use as a cl...

Page 19: ...f persons The following defines persons and their responsibilities Operator The operator is the legal person who uses the industrial robots or industrial robot systems and is responsible for the perso...

Page 20: ...nect the robot arm Create the operating manual for the complete plant machine Issue the declaration of conformity Affix the CE mark Robot operator The robot operator is a person who is assigned with s...

Page 21: ...y All claims to warranty and liability will be rendered invalid if The product was used contrary to the purpose for which it is intended Damage can be attributed to not having followed the guidelines...

Page 22: ...g connection of an external reset device Emergency stop external e g connection of an external emergency stop device Protective stop external e g connection of an external safeguard External safeguard...

Page 23: ...function for protective stop external 27 and Protective stop function for PSENmlock safety gate function 29 Switching operating mode key switch on teach pendant Controlled stop stop cat egory 1 Contr...

Page 24: ...ty or brake test not conducted Controlled stop stop cat egory 1 Controlled stop stop cat egory 1 See section Brake test function 36 Power failure Controlled stop stop category 0 Controlled stop stop c...

Page 25: ...rgency stop pushbutton on the teach pendant i e an external emergency stop pushbutton then its position and wiring will need to be planned see Planning an external emergency stop device 74 Triggering...

Page 26: ...s avail able under Planning an external reset device for an external emer gency stop device 77 If the reset occurs via the teach pendant please note the requirements from the safety standards Restart...

Page 27: ...nal safety devices that are required The position and wiring of the external safety devices will need to be planned see Planning external protective stop devices 75 The protective stop function is onl...

Page 28: ...e stop device 78 NOTICE Manual reset via the teach pendant or via an external reset device The reset can occur either via the teach pendant 2nd button or via an ex ternal reset device depending on the...

Page 29: ...n and wiring of the ex ternal safety devices will need to be planned see Planning external protective stop devices 75 The safety gate function is only effective in automatic operating mode Triggering...

Page 30: ...whether the reset should occur automatically or manu ally Further information is available under Planning an external reset device for a protective stop device 78 Restart after a protective stop It i...

Page 31: ...safety function the holding brakes on the robot arm are checked at regular inter vals by a brake test The safety control system requests a cyclical brake test from the robot controller and evaluates...

Page 32: ...entre position enable If the motion enable from the safety control system is present then the axes of the robot arm can be moved manually for as long as the programmer keeps one or both of the en abli...

Page 33: ...operating mode is changed while the enabling switch is in the centre position the robot movement will come to a controlled stop SS1 For mo tion to be re enabled the enabling device must be released z...

Page 34: ...initiates the following procedure Operate enabling switch centre position Evaluation of switch position Centre position is detected Fig Evaluation of the enabling device when enabling switch is in th...

Page 35: ...depress enabling switch Evaluation of signal Zero position or panic position is detected Check the current operating mode SS1 Manual operating mode Automatic Display is updated teach pendant Fig Evalu...

Page 36: ...from brake test CAN1 Fig Cooperation between safety control system motion controller and robot arm during brake test principle The programmer is tasked with implementing the specified requirements and...

Page 37: ...ical prompt to perform brake test The cyclical brake test is the brake test that is generally prescribed for the robot arm see Brake test function with cyclical brake test 40 Prompt to perform brake t...

Page 38: ...ch the application de pendent brake test position and perform a brake test A message will appear on the teach pendant prompting the robot operator to perform a brake test immediately The safety contro...

Page 39: ...splay on teach pendant SS1 was triggered because the brake test was not performed Fig SS1 due to the brake test not being performed In order to approach the brake test position after an SS1 a time lim...

Page 40: ...ore the monitoring time is exceeded there will be an advance warning Within the next hour it is necessary to approach the spe cified brake position depending on the application and perform a brake tes...

Page 41: ...each pendant SS1 was triggered because the brake test was not performed Fig SS1 due to the brake test not being performed In order to approach the brake test position after an SS1 a time limited motio...

Page 42: ...ains a service program as the default robot program see Default robot program for brake test 46 The service program is started via the Play button First of all the specified brake test pos ition is ap...

Page 43: ...rake test may be necessary if the industrial robot is part of a production line for example The production line is generally controlled by a higher level controller The system or plant integrator is t...

Page 44: ...warning time and monitoring time are re started A corresponding message will appear in the teach pendant Brake test was performed but failed A brake test is deemed to have been performed but have fai...

Page 45: ...rake test Update the monitoring status of the brake test SS1 Display on teach pendant Brake test was performed but failed Yes No Brakes OK Fig Evaluate the result of the brake test In order to approac...

Page 46: ...rake test To do this the programmer must call up the service program at a suitable point in his robot program The system or plant integrator is tasked with determining a time to perform the cyclical b...

Page 47: ...rake test was performed but failed The robot operator must move the robot arm to its transport position within the time for the temporary motion enable see Evaluation of brake test 44 The brakes must...

Page 48: ...works exclusively in automatic operating mode The manual operating modes must be triggered via the key switch on the teach pendant see Operating mode Manual reduced speed 51 and Operating mode Manual...

Page 49: ...1 was triggered Safety control system Enable for Automatic operating mode Configuration Automatic with teach pendant Configuration Automatic with external controller Waiting for Start external control...

Page 50: ...th teach pendant 61 Please note The stop that is triggered via the stop button corresponds to a controlled stop of the robot movement i e this stop does not trigger the stop function SS1 Start stop in...

Page 51: ...In this operating mode if the signal changes from 1 to 0 at the input Protective stop ex ternal or Protective stop external safeguard PSENmlock 1 or 2 this will be ignored The robot movement will not...

Page 52: ...SS1 was triggered Safety control system Enable for operating mode Manual reduced speed Waiting for manual motion input controlled stop Operate control button with enable Movement at reduced speed No...

Page 53: ...ach pendant is not operated the stop function SS1 is triggered CAUTION Risk due to inactive safeguards If you switch from one of the manual operating modes into automatic oper ating mode before the fu...

Page 54: ...nored The robot movement will not come to a controlled stop SS1 If you switch from this operating mode into one of the other operating modes the robot movement will come to a controlled stop see Chang...

Page 55: ...motion input controlled stop Operate control button and select required speed Movement at high speed Motion program ended Speed is reset to the initial speed limit 250 mm s No enable Fig Robot moveme...

Page 56: ...this case the teach pendant can be used to again select speed values up to the maximum speed NOTICE If the operating mode Manual high speed is active and there is no enable from the enabling device f...

Page 57: ...different operating mode proceed as follows Turn the key switch on the teach pendant from Lock to Unlock Change the operating mode on the teach pendant An overview of the possible changes of operatin...

Page 58: ...rating mode Manual high speed is automatically deactivated and switches simultan eously to Manual reduced speed NOTICE In one of the manual operating modes if the enable has been continuously present...

Page 59: ...P1_100 235 02 ms Stopping time at 66 of maximum speed vAxis 60 s tstopping_STOP1_66 168 35 ms Stopping time at 33 of maximum speed vAxis 30 s tstopping_STOP1_33 101 69 ms Stopping distance at maximum...

Page 60: ...e from the moment the STO signal on the robot arm is reset until the moment at which all brakes are engaged tcomplete_stopping tstopping_STOP1_100 tBrake The following values are used to calculate tco...

Page 61: ...ol system is present Starting the robot program via the teach pendant Start the robot program that is currently selected by operating the Play button on the teach pendant The teach pendant starts the...

Page 62: ...e outputs Status ready external and Status running external are available on the motion controller to enable the robot pro gram to be started stopped and reset externally For external control of the r...

Page 63: ...nning external for as long as the motion enable is present see Status ready external 4 The current robot program is started see Status running external when the mo tion enable is present see Status re...

Page 64: ...ion controller sets the output Status running external to 0 when at least one of the following conditions is met The operating mode Automatic external is not active The motion enable is not present ou...

Page 65: ...Reset external changes from 0 to 1 while there is a 1 signal at the input Start external the movement of the robot arm is stopped and the motion con troller resets the program counter back to the sta...

Page 66: ...te systems Legend World coordinate system The coordinates of the world coordinate system refer to the workspace Axes of the coordinate system XBase YBase ZBase Robot coordinate system The robot coordi...

Page 67: ...bot arm the TCP moves from the flange TCP to the end effector TCP TCP transformation The translation of the TCP from the flange TCP to the end effector TCP is called TCP transformation A TCP transform...

Page 68: ...Flange ZFlange YFlange XFlange KSFlange KSRobot KSFlange ZRobot XRobot YRobot ZRobot XRobot YRobot Joint 3 Joint 2 Joint 1 Fig Positions in the robot coordinate system when all axes are in zero positi...

Page 69: ...stem is right oriented which gives the resulting direc tions of the axes If all the axes of the robot arm are in zero position then the orienta tion of the flange coordinate system is identical to tha...

Page 70: ...program Digital FS and ST inputs Digital FS outputs Communication interface for communication with the motion controller Motion controller from Pilz including Pre installed motion control user progra...

Page 71: ...control user program Motion controller CANopen Master End effector Indicator lamp Status Teach pendant Voltage supply 230 V AC Low voltage power supply Safety gate with guard locking Emergency stop En...

Page 72: ...ition closed safety gate In the test position the robot arm is not to be gravity loaded at all or if so only slightly otherwise an additional force is acting on the holding brakes which unnecessarily...

Page 73: ...is 2 Connecting element 1 see 2 is positioned vertically Axis 3 0 position of axis 3 Joint 2 points with axis 4 vertically upwards Axis 4 0 position of axis 4 Connecting element 2 see 3 points in the...

Page 74: ...pushbutton must be connected to the dedicated dual channel FS input for Emergency stop external see Connections for external devices 86 Module A1 2 terminals 11 Emergency stop external channel 1 OK M...

Page 75: ...channel 1 OK Module A1 3 terminal 14 Protective stop external safeguard 1 channel 2 OK Protective stop external safeguard PSENmlock 2 Safety output Module A1 8 terminal 11 Protective stop external saf...

Page 76: ...The system or plant integrator must determine whether the reset is to occur automatically or whether a manual reset is required Reset via the teach pendant or via an external reset device The system...

Page 77: ...in his risk analysis If the risk analysis shows that an external emergency stop device is needed then in the control cabinet the corresponding external reset device must be con nected to the dedicated...

Page 78: ...the state that triggered the stop has been rectified an automatic reset is the result For an automatic reset in the control cabinet the two dedicated FS inputs must be perman ently connected to a 1 si...

Page 79: ...r external devices 86 Module A1 3 terminal 21 Setting option protective stop external restart channel 1 Module A1 3 terminal 24 Setting option protective stop external restart channel 2 For example fo...

Page 80: ...al brake test In the control cabinet an output on the higher level controller must be connected to the ded icated FS input Prompt for manual brake test see Connections for external devices 86 Module A...

Page 81: ...the operating manual for the overall plant machine contains the up to date application dependent cir cuit diagram NOTICE Information on the wiring can be found in the operating manual for the robot c...

Page 82: ...tion Interval period Required measure Test STO connection between control cabinet and robot arm Before each initial commission ing In accordance with the require ments from the risk analysis 1 Enable...

Page 83: ...emergency stop pushbut ton on the teach pendant Result The STO LED at the foot of the robot arm must light up red In diagnostic view for the safety control system a message must appear on the teach pe...

Page 84: ...e system or plant integrator must ensure that the requirements for the setting up and the assembly are complied with NOTICE Please refer to the information and requirements in the operating manual for...

Page 85: ...ng plug see Accessories 116 must be plugged into the 20 pin socket con nector on the control cabinet label in the operating manual for the robot control module PRCM1 20XS1 if the teach pendant is not...

Page 86: ...ion prompting reset and configuration of external safety devices are pre prepared Device Implementation safety control sys tem Operating manual for robot control module PRCM1 Mod ule Terminal configur...

Page 87: ...uit diagram for channel 2 Protective stop external channel 2 OK Terminal 24 Input I3 Terminal 23 Test pulse output T1 Delivery condition Jumper terminals 24 23 Protective stop external safeguard PSENm...

Page 88: ...output T1 Delivery condition No automatic re start i e no jumper terminals 24 23 Reset for protective stop on external safeguards Protective stop external Protective stop external safeguards PSENm loc...

Page 89: ...tput PSSu E F 4DI Digital FS input Dual channel Test pulse via ex ternal safeguard 2 PSENmlock A1 8 11 Label in circuit diagram Protective stop external safeguard 2 channel 1 OK Terminal 11 Input I0 T...

Page 90: ...y supply Delivery condition No external wir ing 21 Label in circuit diagram Activate external safeguard 1 PSENmlock lock unlock channel 2 Terminal 21 Output O1 Terminal 22 0 V periphery supply Deliver...

Page 91: ...ency stop external Status of robot arm PSSu E F 2DOR 8 2 monitored relay outputs Dual channel A1 7 11 12 Label in circuit diagram Local emergency stop channel 1 OK Output O0 11 21 Relay contacts 1 and...

Page 92: ...g the appropriate procedures for the industrial robot depending on the application Please note the requirements of any applica tion dependent circuit diagram see Circuit diagram 81 The following input...

Page 93: ...binet All the labels in the table below corres pond to the labels in the wiring diagram see operating manual for the robot control mod ule PRCM1 Assignment of X1 Power Core number Wiring destination T...

Page 94: ...pond to the labels in the wiring diagram see operating manual for the robot control module PRCM1 Assignment of X3 AUX Core colour Abbr Colour Wiring destination Terminal Connection Wiring destination...

Page 95: ...y connecting the cables while voltage is ap plied Connecting cables while voltage is applied may result in malfunctions Ensure that all cables are only connected in the de energised state Procedure Co...

Page 96: ...n socket connector on the control cabinet label in the operating manual for the robot control module PRCM1 20XS1 otherwise the robot program cannot be started NOTICE Malfunctions caused by inserting r...

Page 97: ...bot control module PRCM1 have been adhered to The robot arm is wired properly The requirements from the Wiring section the operat ing manual for the robot arm PRBT 6 and the operating manual for the r...

Page 98: ...plication in jury or material damage may occur if the calculated values for stopping time overrun distance are not validated The system or plant integrator must ensure that the values calculated in th...

Page 99: ...ty gates are closed Switch to the operating mode Automatic with teach pendant Operate the reset button on the teach pendant 2nd button to request the motion enable Test the emergency stop function Ope...

Page 100: ...op pushbuttons are unlocked Ensure that all safety gates are closed Switch to the operating mode Automatic with teach pendant Operate the reset button on the teach pendant 2nd button to request the mo...

Page 101: ...the changes will affect the SIL PL The change requirements can be combined into a catalogue of requirements This should include Detected hazards Desired changes Reason for the changes The change shoul...

Page 102: ...arried out only in the de energised state Before you start disassembling switch off the supply voltage at the control cabinet main switch and disconnect the supply voltage cable Prerequisites The robo...

Page 103: ...em Uninstall the motion controller and or safety control system swap the robot control module for a compatible control cabinet and install the motion controller and or safety control system in the new...

Page 104: ...application The wiring diagram for the application is available The supply voltage has been switched off at the control cabinet main switch The supply voltage cable for the robot control module has be...

Page 105: ...ftware on the teach pendant has been saved on a supported USB storage medium e g USB stick The wiring diagram for the application is available The supply voltage has been switched off via the control...

Page 106: ...f at the control cabinet main switch A robot arm with identical version is available as the exchange device Procedure Remove all connections from the robot arm and uninstall the robot arm Refer to the...

Page 107: ...s You will find the information in the section entitled Safety characteristic data under Technical details Procedure Before the robot arm can be decommissioned it must be moved to its transport positi...

Page 108: ...cal and Electronic Equipment Act NOTICE Information regarding the mission time TM is documented in the operating manual for the service robotics modules You will find the information in the section en...

Page 109: ...cable is damaged Check the connector for damage and exchange any damaged connector STO LED at the foot of the robot arm lights up red Motion enable is not present because the emergency stop function...

Page 110: ...ion cable on the teach pendant is damaged Please contact Pilz The connector plug is damaged Please contact Pilz The teach pendant is defective Please contact Pilz Fault The motion controller and safet...

Page 111: ...y characteristic data NOTICE You must comply with the safety characteristic data in order to achieve the required safety level for your plant machine The list below contains an overview of the safety...

Page 112: ...SRCF 02 is determined by the following components Safety controller from the automation system PSS 4000 Robot arm External interfaces 1 x digital FS input 2 channel SRCF 03 Protective stop function fo...

Page 113: ...on the teach pendant for moving the axes manually in a manual operating mode Safety controller from the automation system PSS 4000 Robot arm External interfaces None SRCF 05 Safety function Locking th...

Page 114: ...ontroller from the automation system PSS 4000 External interfaces 1 x digital FS output 2 channel SRCF 7 1 SRCF 7 2 Protective stop function for automatic operating mode Ex ternal safety device PSENml...

Page 115: ...rder no PRCM1 Robot control module Complete control cabinet Safety control system PSS 4000 CNC PMCprimo MC Robotics FS function blocks 9C000001 Product type Features Order no PRTM1 5 m Robot teach mod...

Page 116: ...ndows Embedded Standard 7 operating system PRTMvisu Connection cable 10 m 9D000007 13 2 Accessories Service robotics module PRBT 6 Product type Features Order no PRBTcable X1 M12L5f 5m Connection cabl...

Page 117: ...der no PRTM1 wmount Wall holder for PRTM1 Including cable bracket 9D000004 PRTM1 bplug Bridging plug for PRTM1 9D000003 End effectors Product type Features Order no PG 070 Gripper with CANopen interfa...

Page 118: ...des a so called electronic fingerprint The hash value of the ori ginal file can be used to check the integrity of the downloaded file after downloading To do this the hash value of the downloaded file...

Page 119: ...en the command prompt application cmd exe 2 Go to the directory containing the file 3 Calculate the hash value of the required file using certutil hashfile file encryption algorithm File File name in...

Page 120: ...PowerShell application 2 Go to the directory containing the file 3 Calculate the hash value of the required file using get filehash algorithm encryption algorithm file Format List File File name in s...

Page 121: ...d to the state of the art the downloaded file is acceptable to use Note In principle it is sufficient to compare the starts and the ends of the two hash values If you want to be sure you can make life...

Page 122: ...te version z B v1_1_0 Content and hash value of the zip file PRTM1 Firmware Version Content and hash value V1 1 0 Content PRTM1 operating system PRTMvisu PMCprimo MC application program PMCprimo MC fi...

Page 123: ...automation technology The industrial robot comprises The manipulator including sensors and actuators The control unit including programming teach pendant as well as the communication in terface hardw...

Page 124: ...ndix System Description Service Robotics Modules 1004870 EN 05 124 Comment The robot program is transmitted by the teach pendant to the motion controller where it is run by the motion control user pro...

Page 125: ...energy efficient products and environmentally friendly solutions We are represented internationally Please refer to our homepage www pilz com for further details or contact our headquarters Headquart...

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