ABB-S4C-Product Manual IRB 2400 3HAC 5644-1 M98A

Product Manual IRB 24003HAC 5644-1 M98A Please Click the Picture to continue www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete ABB Flexible Automation The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge. © ABB Robotics Products AB Article number: 3HAC 5644-1 Issue: M98A ABB Robotics Products AB S-721 68 Västerås Sweden www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Table of Contents 1 2 3 4 5 6 Introduction Product Specifications Safety Certificates Configuration list System Description 7 Installation and Commissioning 8 9 10 11 12 13 14 Maintenance Troubleshooting Tools Fault Tracing Guide Circuit Diagrams Repairs Spare Parts Decommissioning www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Introduction CONTENTS Page 1 How to use this Manual........................................................................................... 3 2 What you must know before you use the Robot ................................................... 3 3 Identification ............................................................................................................ 4 www.cadfamily.com EMail:[email protected] Product Manual The document is for study only,if tort to your rights,please inform us,we will delete 1 Introduction www.cadfamily.com EMail:[email protected] 2 Product Manual The document is for study only,if tort to your rights,please inform us,we will delete Introduction Introduction 1 How to use this Manual This manual provides information on installation, preventive maintenance, troubleshooting and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation. Anyone reading this manual should also have access to the User’s Guide. The chapter entitled System Description provides general information on the robot structure, such as its computer system, input and output signals, etc. How to assemble the robot and install all signals, etc., is described in the chapter on Installation and Commissioning. If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults. Servicing and maintenance routines are described in the chapter on Maintenance. 2 What you must know before you use the Robot • Normal maintenance and repair work usually only require standard tools. Some repairs, however, require specific tools. These repairs, and the type of tool required, are described in more detail in the chapter Repairs. • The power supply must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orangecoloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller. • Circuit boards - printed boards and components - must never be handled without Electro-Static-Discharge (ESD) protection in order not to damage them. Use the carry band located on the inside of the controller door. All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone. www.cadfamily.com EMail:[email protected] Product Manual The document is for study only,if tort to your rights,please inform us,we will delete 3 Introduction 3 Identification Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2). The BaseWare O.S diskettes are also marked with serial number (see Figure 3). Note! The identification plates and label shown in the figures below, only serves as examples. For exact identification, see plates on your robot in question. ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Type: Robot version: Man. order: Nom. load Serial. No: Date of manufacturing: Net weight 2,4.120 : 1870 kg 2,4-150 : 2010 kg 2,8-120 : 2010 kg IRB 6400 M98 IRB 6400/2.4-150 XXXXXX See instructions 6400-XXXX 1997-XX-XX 3.0-75 : 2010 kg S/2,9-120 : 2240 kg PE/2,25-75 : 1590 kg Identification plate showing the IRB 6400 IRB 140(0) IRB 2400 IRB 6400 IRB 4400 IRB 640 IRB 340 IRB 840/A Figure 1 Example of identification plate and its location on different manipulator types. www.cadfamily.com EMail:[email protected] 4 Product Manual The document is for study only,if tort to your rights,please inform us,we will delete Introduction . ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Type: Robot version: Voltage: 3 x 400 V Power: Man. order: Re.No: Serial. No: Date of manufacturing: Net weight: IRB 6400 M98 IRB 6400/2.4-150 Frequency: 50-60 Hz 7.2 kVA XXXXXX RXXXXXXXXXX 64-XXXXX 1998-XX-XX 240 kg Figure 2 Identification plate on the controller. 64-00000 System Key S4C 3.1 Program No 3 HAB2390-1/03 B o o t d i s k 1 (1) Property of ABB Västerås/Sweden. All rights reserved. Reproduction, modification, use or disclosure to third parties without express authority is strictly forbidden. Copyright 1993. Restricted to be used in the controller(s) with the serial no as marked on disk. ABB Robotics Products AB Figure 3 Example of a label on a BaseWare O.S diskette. www.cadfamily.com EMail:[email protected] Product Manual The document is for study only,if tort to your rights,please inform us,we will delete 5 Introduction www.cadfamily.com EMail:[email protected] 6 Product Manual The document is for study only,if tort to your rights,please inform us,we will delete Product Specification IRB 2400 CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 Description ....................................................................................................................... 5 2.1 Structure.................................................................................................................. 5 2.2 Safety/Standards ..................................................................................................... 6 2.3 Operation ................................................................................................................ 7 2.4 Installation .............................................................................................................. 9 2.5 Programming .......................................................................................................... 9 2.6 Automatic Operation .............................................................................................. 11 2.7 Maintenance and Troubleshooting ......................................................................... 12 2.8 Robot Motion.......................................................................................................... 13 2.9 External Axes ......................................................................................................... 16 2.10 Inputs and Outputs................................................................................................ 16 2.11 Serial Communication .......................................................................................... 17 3 Technical specification .................................................................................................... 19 3.1 Structure.................................................................................................................. 19 3.2 Safety/Standards ..................................................................................................... 22 3.3 Operation ................................................................................................................ 23 3.4 Installation .............................................................................................................. 24 3.5 Programming .......................................................................................................... 33 3.6 Automatic Operation .............................................................................................. 37 3.7 Maintenance and Troubleshooting ......................................................................... 37 3.8 Robot Motion.......................................................................................................... 38 3.9 External Axes ......................................................................................................... 41 3.10 Inputs and Outputs................................................................................................ 42 3.11 Communication..................................................................................................... 46 4 Specification of Variants and Options........................................................................... 47 5 Accessories ....................................................................................................................... 63 6 Index ................................................................................................................................. 65 www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 1 1 The document is for study only.if tort to your rights.we will delete .Product Specification IRB 2400 www.please inform us.com 2 Product Specification IRB 2400 M98A/BaseWare OS 3.cadfamily.com EMail:cadserv21@hotmail. RAPID Reference Manual and Product Manual. BaseWare OS controls every aspect of the robot. designed specifically for manufacturing industries that use flexible robot-based automation. communication features . sensor control etc. foundry) Indicates the maximum handling capacity (kg) 3 Description www.cadfamily.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. The robot is equipped with an operating system called BaseWare OS. development and execution of application programs communication etc.comOS 3. like motion control. Different robot versions The IRB 2400 is available in different versions depending on its handling capacity and environment protection. The following robot versions are available. floor mounting or inverted: Robot Versions IRB 2400L IRB 2400/10 IRB 2400/16 IRB 2400FL IRB 2400F/10 IRB 2400F/16 Definition of version designation IRB 2400 Application / Reach .and advanced functions such as multitasking. if not otherwise specified.network communication . This manual will give you an overview of the characteristics and performance of the robot. and can communicate extensively with external systems.g.gluing. or contact your nearest ABB Flexible Automation Centre. The robot has an open structure that is specially adapted for flexible use.we will delete . The functions in this document are all included in BaseWare OS. the robot can be equipped with optional software for application support . For complete information on optional software. IRB 2400 is a 6-axis industrial robot. For a more complete and detailed description. All the features are not described in this document.if tort to your rights. arc welding for example. For additional functionality.Handling capacity Prefix Version Application Handling capacity L F yy Long arm Manipulator adapted for use in harsh environments (e. please see the User’s Guide.Introduction 1 Introduction Thank you for your interest in the IRB 2400.please inform us. see the Product Specification RobotWare.com EMail:cadserv21@hotmail. www. The most important technical data is listed in Chapter 3: Technical specification. Note that the sections in chapter 2 and 3 are related to each other. The Product Specification RobotWare describes the software options. In Chapter 5 you will find accessories for the robot. The Product Manual describes how to install the robot.1 The document is for study only.2 you can find more detailed information.com EMail:[email protected] 4 Product Specification IRB 2400 M98A/BaseWare OS 3. in section 2.Introduction How to use this manual The characteristics of the robot are described in Chapter 2: Description.cadfamily. To make sure that you have ordered a robot with the correct functionality. The programming language is described in the RAPID Reference Manual.please inform us. as well as maintenance procedures and troubleshooting. see Chapter 4: Specification of Variants and Options. in section 3. Chapter 6 contains an Index. to make things easier to find.if tort to your rights.2 you can find an overview of safety and standards.we will delete . Other manuals The User’s Guide is a reference manual with step by step instructions on how to perform various tasks. For example. we will delete 5 . external axes and peripheral equipment. The controller contains the electronics required to control the manipulator.1 Structure The robot is made up of two main parts: a manipulator and a controller.comOS 3. Teach pendant Operator´s panel Mains switch Disk drive Figure 2 The controller is specifically designed to control robots.com EMail:[email protected] inform us. which means that optimal performance and functionality is achieved.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.Description 2 Description 2. Axis 4 Axis 5 Axis 6 Axis 3 Axis 2 Axis 1 Figure 1 The IRB 2400 manipulator has 6 axes.cadfamily. www.if tort to your rights. Description 2.2 Safety/Standards The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives as well as ANSI/RIA 15.06-1992. The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.). The speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot. Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate. Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Over-speed protection The speed of the robot is monitored by two independent computers. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. Safeguarded space stop The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at normal program stop with no deviation from the programmed path. After approx. one second the power supplied to the motors shuts off. www.cadfamily.com EMail:[email protected] 6 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete Description Restricting the working space The movement of each of the axes can be restricted using software limits. Axes 1 and 2 can also be restricted by means of an adjustable mechanical stop. Axis 3 can be restricted using an electrical limit switch. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the key is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety. Safety lamp As an option, the robot can be equipped with a safety lamp. This is activated when the motors are in the MOTORS ON state. 2.3 Operation All operations and programming can be carried out using the portable teach pendant (see Figure 3) and the operator’s panel (see Figure 5). 7 4 1 Display 1 2 8 5 2 0 9 6 3 Joystick P1 P2 P3 Emergency stop button Figure 3 The teach pendant is equipped with a large display, which displays prompts, information, error messages and other information in plain English. Information is presented on a display using windows, pull-down menus, dialogs and function keys. No previous programming or computer experience is required to learn how to operate the robot. All operation can be carried out from the teach pendant, which means that a specific keyboard is not required. All information, including the complete programming language, is in English or, if preferred, some other major language. www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 7 Description Menu keys Edit View 1 Goto ... Inputs/Outputs 2 Goto Top 3 Goto Bottom Name Value di1 di2 grip1 grip2 clamp3B feeder progno welderror 1 0 1 0 1 0 1 1 13 0 File Menu 4(64) Line indicator I/O list Cursor Function keys Figure 4 Window for manual operation of input and output signals. Using the joystick, the robot can be manually jogged (moved). The user determines the speed of this movement; large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly. The robot supports different user levels, with dedicated windows for: - Production - Programming - System setup - Service and installation Operator’s panel Motors On button and indicating lamp Operating mode selector Emergency stop Duty time counter Figure 5 The operating mode is selected using the operator’s panel on the controller. www.cadfamily.com EMail:[email protected] 8 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete Description Using a key switch, the robot can be locked in two or three different operating modes: • Automatic mode: • Manual mode at reduced speed: 100% Running production Programming and setup Max. speed: 250 mm/s (600 inches/min.) Testing at full program speed Manual mode at full speed (option): Equipped with this mode, the robot is not approved according to ANSI/UL Both the operator’s panel and the teach pendant can be mounted externally, i.e. outside the cabinet. The robot can then be controlled from there. The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals. For more information on how to operate the robot, see the User’s Guide. 2.4 Installation The robot has a standard configuration and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the teach pendant. The configuration can be stored on a diskette and/or transferred to other robots that have the same characteristics. The same version of the robot can, with a simple change in the balancing system, either be mounted on the floor or inverted. An end effector, max. weight 5, 10 or 16 kg including payload, can be mounted on the robot’s mounting flange (axis 6) depending on the robot version. Other equipment can be mounted on the rear of the upper arm, max. weight 11 or 12 kg, and on the base, max. weight 35 kg. 2.5 Programming Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”. The programming environment can be easily customised using the teach pendant. - Shop floor language can be used to name programs, signals, counters, etc. - New instructions can be easily written. - The most common instructions can be collected in easy-to-use pick lists. - Positions, registers, tool data, or other data, can be created. Programs, parts of programs and any modifications can be tested immediately without having to translate the program. The program is stored as a normal PC text file, which means that it can be edited using a standard PC. www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 9 Description Movements A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move. The positions of a motion instruction are selected either by manually jogging the robot to the desired position with the joystick, or by referring to a previously defined position. The exact position can be defined (see Figure 6) as: - a stop point, i.e. the robot reaches the programmed position; or - a fly-by point, i.e. the robot passes close to the programmed position. The size of the deviation is defined independently for the TCP, the tool orientation and the external axes. Stop point Fly-by point User-definable distance (in mm) Figure 6 The fly-by point reduces the cycle time since the robot does not have to stop at the programmed point.The path is speed independent. The velocity may be specified in the following units: - mm/s - seconds (time it takes to reach the next programmed position) - degrees/s (for reorientation of the tool or for a rotation of an external axis) Program management For convenience, the programs can be named and stored in different directories. Areas of the robot’s program memory can also be used for program storage. This gives a very fast memory where you can store programs. These can then be automatically downloaded using an instruction in the program. The complete program or parts of programs can be transferred to/from a diskette. Programs can be printed on a printer connected to the robot, or transferred to a PC where they can be edited or printed. Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane. www.cadfamily.com EMail:[email protected] 10 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete Description A robot position can easily be changed either by: - jogging the robot with the joystick to a new position and then pressing the “ModPos” key (this registers the new position) or by - entering or modifying numeric values. To prevent unauthorised personnel making program changes, passwords can be used. Testing programs Several helpful functions can be used when testing programs. For example, it is possible to - start from any instruction - execute an incomplete program - run one cycle - execute forward/backward step-by-step - simulate wait conditions - temporarily reduce the speed - change a position - tune (displace) a position during program execution. For more information, see the User´s Guide and RAPID Reference Manual. 2.6 Automatic Operation A dedicated production window with commands and information required by the operator is automatically displayed during automatic operation. The operation procedure can be customised to suit the robot installation by means of user-defined operating dialogs. Select program to run: Front A Front B Front C Other SERVICE Figure 7 The operator dialogs can be easily customised. www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 11 Description A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution. You can also create special routines that will be automatically executed when the power is switched on, at program start and on other occasions. This allows you to customise each installation and to make sure that the robot is started up in a controlled way. The robot is equipped with absolute measurement, making it possible to operate the robot directly from when the power is switched on. For your convenience, the robot saves the used path, program data and configuration parameters so that the program can easily be restarted from where you left off. Digital outputs are also set automatically to the value before the power failure. 2.7 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - Maintenance-free AC motors are used. - Oil is used for the gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change. - The controller is enclosed, which means that the electronic circuitry is protected when operating in a normal workshop environment. - It has a program memory “battery low” alarm. The robot has several functions to provide efficient diagnostics and error reports: - It performs a self-test when power on is set. - Errors are indicated by a message displayed in plain language. The message includes the reason for the fault and suggests recovery action. - A board error is indicated by an LED on the faulty unit. - Faults and major events are logged and time-stamped. This makes it possible to detect error chains and provides the background for any downtime. The log can be read on the display of the teach pendant, stored in a file and also printed on a printer. - There are commands and service programs in RAPID to test units and functions. Most errors detected by the user program can also be reported to and handled by the standard error system. Error messages and recovery procedures are displayed in plain language. www.cadfamily.com EMail:[email protected] 12 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete Description 2.8 Robot Motion IRB 2400L 3421 1702 5 R= 21 2885 560 100 1810 IRB 2400/10 IRB 2400/16 2900 1441 4 R= 48 2458 393 100 1550 Figure 8 Working space of IRB 2400 (dimensions in mm). www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 13 Description Motion performance The QuickMoveTM concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement. - No parameters have to be adjusted to achieve correct path, orientation and velocity. - Maximum acceleration is always obtained (acceleration can be reduced, e.g. when handling fragile parts). - The number of adjustments that have to be made to achieve the shortest possible cycle time is minimized. The TrueMoveTM concept means that the programmed path is followed – regardless of the speed or operating mode – even after an emergency stop, a safeguarded stop, a process stop, a program stop or a power failure. The robot can, in a controlled way, pass through singular points, i.e. points where two axes coincide. Coordinate systems Tool Centre Point (TCP) Y Tool coordinates Z Z X Y Base coordinates Z X Z Z User coordinates Y Y World coordinates X Figure 9 The coordinate systems, used to make jogging and off-line programming easier. X Object coordinates Y X The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop. The world coordinate system is also very useful when two robots work together or when using a robot carrier. www.cadfamily.com EMail:[email protected] 14 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete Description The base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tool’s centre point and orientation. The user coordinate system specifies the position of a fixture or workpiece manipulator. The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator. The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed). Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool. If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined. Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object. Program execution The robot can move in any of the following ways: - Joint motion (all axes move individually and reach the programmed position at the same time) - Linear motion (the TCP moves in a linear path) - Circle motion (the TCP moves in a circular path) Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur. If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part. www.cadfamily.com EMail:[email protected] 3.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only,if tort to your rights,please inform us,we will delete 15 Description Jogging The robot can be manually operated in any one of the following ways: - Axis-by-axis, i.e. one axis at a time - Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate systems mentioned above) - Reoriented around the TCP It is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved. During manual operation, the current position of the robot and the external axes can be displayed on the teach pendant. 2.9 External Axes The robot can control up to six external axes. These axes are programmed and moved using the teach pendant in the same way as the robot’s axes. The external axes can be grouped into mechanical units to facilitate, for example, the handling of robot carriers, workpiece manipulators, etc. The robot motion can be simultaneously coordinated with a one-axis linear robot carrier and a rotational external axis. A mechanical unit can be activated or deactivated to make it safe when, for example, manually changing a workpiece located on the unit. In order to reduce investment costs, any axes that do not have to be active at the same time can use the same drive unit. Programs can be reused in other mechanical units of the same type. 2.10 Inputs and Outputs A distributed I/O system is used, which makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. A number of different input and output units can be installed: - Digital inputs and outputs - Analog inputs and outputs - Remote I/O for Allen-Bradley PLC - InterBus-S Slave - Profibus DP Slave www.cadfamily.com EMail:[email protected] 16 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only,if tort to your rights,please inform us,we will delete 1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. 2. feeder .List all the signal values .e.11 Serial Communication The robot can communicate with computers or other equipment via RS232/RS422 serial channels or via Ethernet. i.we will delete 17 .g.Description The inputs and outputs can be configured to suit your installation: . see Product Specification RobotWare. this will not have any visible effect on the robot motion. normal program execution resumes. In most cases. entering a bar code Signals can be assigned to special system functions. Requires option Multitasking. Manual commands are available to: . . so as to be able to control the robot from an external panel or PLC.Background programs (for monitoring signals.com EMail:[email protected] your own list of your most important signals .I/O mapping (i.Up to 16 digital signals can be grouped together and used as if they were a single signal when. gripper. The robot can work as a PLC by monitoring and controlling I/O signals: .Cross connections . a physical connection for each signal) .Manually change the status of an output signal .please inform us.Each signal and board can be given a name. However this requires optional software.cadfamily. I/O signals can also be routed to connectors on the upper arm of the robot.) . Following this. for example. e.Inputs can be connected to trap routines.Polarity (active high or low) .if tort to your rights. (When such an input is set.I/O instructions can be executed concurrent with the robot motion. if a limited number of instructions are executed in the trap routine. such as program start.comOS 3. www.Print signal information on a printer Signal connections consist of either connectors or screw terminals. see the Product Specification RobotWare. for example) can be run in parallel with the actual robot program. which are located in the controller. the trap routine starts executing. please inform us.com 18 Product Specification IRB 2400 M98A/BaseWare OS 3.if tort to your rights.1 The document is for study only.we will delete .Description www.cadfamily.com EMail:cadserv21@hotmail. cadfamily.Technical specification 3 Technical specification Applies to standard and Foundry versions unless otherwise stated. 3.comOS 3.please inform us.we will delete 19 .if tort to your rights.1 Structure Weight: Volume: Manipulator Controller Controller 380 kg 240 kg 950 x 800 x 540 mm < 70 dB (A) Leq (acc.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.com EMail:cadserv21@hotmail. to Machinery directive 89/392 EEC) Airborne noise level: The sound pressure level outside the working space 50 540 800 Cabinet extension Option 115 800 Extended cover Option 114 250 500 200 950 980 * Lifting points for forklift * Castor wheels 500 Figure 10 View of the controller from the front and from above (dimensions in mm). www. rear and above (dimensions in mm).cadfamily.please inform us.Technical specification IRB 2400L 1225 870 290 360 65 260 150 855 1730 176 268 251 138 615 446 180 100 305 723 C L 454 600 R=448 R=76 444 R=347 123 A A-A A 389 R=330 Figure 11 View of the manipulator from the side.we will delete .1 The document is for study only.if tort to your rights. www.com 20 Product Specification IRB 2400 M98A/BaseWare OS 3.com EMail:cadserv21@hotmail. rear and above (dimensions in mm).we will delete 21 .if tort to your rights.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. www.please inform us.comOS 3.com EMail:[email protected] specification IRB 2400/10 IRB 2400/16 1065 180 755 85 306 133 135 705 1564 176 268 251 138 615 446 180 100 305 723 R=98 C L 600 454 R=448 A-A R=347 444 78 85 389 R=330 (163) A A Figure 12 View of the manipulator from the side.cadfamily. Generic emission EN 50082-2 EMC.please inform us. technical specifications EN 954-1 Safety of machinery.06/1992 Industrial robots.General Safety Requirements Safeguarded space stops via inputs External safety equipment can be connected to the robot’s two-channel emergency stop chain in several different ways (see Figure 13). General mode safeguarded space stop External emergency stop Emergency stop 250 mm/s 100% Operating mode selector Auto mode safeguarded space stop M ~ Teach pendant Enabling device Note.cadfamily.if tort to your rights.Technical specification 3. EN 60204-1 accepts one channel circuit without monitoring. safety ANSI/RIA 15. 1. EN 775 Manipulating industrial robots. Manual mode 100% is an option Figure 13 All safeguarded space stops force the robot’s motors to the MOTORS OFF state. terminology EN 292-2 Safety of machinery. safety requirements ISO 9787 Manipulating industrial robots. mechanical interfaces ANSI/UL 1740-1996 (option) Safety Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 424-94 (option) Industrial Robots and Robot Systems .4.we will delete . There is a deviation from the extra demand for only electromechanical components on emergency stop of category 0 in paragraph 9.com 22 Product Specification IRB 2400 M98A/BaseWare OS 3. where the demand for redundancy is founded. coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC. instead the design is made to comply with category 3 according to EN 954-1. www. Generic immunity ISO 9409-1 Manipulating industrial robots. A time delay can be connected to any safeguarded space stop.com EMail:[email protected]. safety related parts of control systems 1 EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery.1 The document is for study only.5. 3 Operation Hold-to-run Menu keys Motion keys P5 Window keys 7 4 1 1 2 8 5 2 0 9 6 3 P4 Joystick Display P1 P2 P3 Enabling device Function keys Navigation keys Figure 14 The teach pendant is very easy to use since any functions provided via the function and menu keys are described in plain language.comOS 3. reorientation or axis-by-axis movement.if tort to your rights.Jogging (manual operation) .Technical specification 3. Menu keys Display pull-down menus.cadfamily. Function keys Select the commands used most often. editing and testing a program .Manual input/output management .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.please inform us.Programming.we will delete 23 .Automatic operation www.System configuration .com EMail:cadserv21@hotmail. Navigation keys Move the cursor and enter data. Display 16 text lines with 40 characters per line.Service and troubleshooting . Window keys Display one of the robot’s various windows.File management . These windows control a number of different functions: . Motion keys Select the type of movement for robot or external axis when jogging: linear movement. The remaining keys can perform only one function each. 95% at constant temperature Complete robot during operation Max.com 24 Product Specification IRB 2400 M98A/BaseWare OS 3.1 The document is for study only.-15% 48.5 to 61.com EMail:[email protected]. open/close gripper) or to activate a system input (see chapter 3. +10%.if tort to your rights.5-14.cadfamily.4 kVA 1000 h (rechargeable battery) www. Ambient temperature Manipulator during operation +5oC (41oF) to +45oC (113oF) Controller during operation +5oC (41oF) to +52oC (125oF) Complete robot during transportation and storage -25oC (13oF) to +55oC (131oF) Relative humidity Complete robot during transportation and storage Max. 3p (3p + N for certain options). 95% at constant temperature Power supply Mains voltage Mains frequency Rated power (transformer size): Absolute measurement backup Configuration The robot is very flexible and can. easily be configured to suit the needs of each user: Authorisation Most common I/O Instruction pick list Instruction builder Operator dialogs Language Date and time Password protection for configuration and program window User-defined lists of I/O signals User-defined set of instructions User-defined instructions Customised operator dialogs All text on the teach pendant can be displayed in several languages Calendar support 200-600V.we will delete .Technical specification User-defined keys Five user-defined keys that can be configured to set or reset an output (e.please inform us.8 Hz 4. 3. by using the teach pendant.4 Installation Operating requirements Protection standards Normal Manipulator Wrist Controller Manipulator Wrist Controller IEC529 IP54 IP54 IP54 IP55 IP67 IP54 IRB 2400F Explosive environments The robot must not be located or operated in an explosive environment.10). 5 (2x) B-B 48 20 D=35 +0.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. group I/O Configuration For a detailed description of the installation procedure.5 0. common drive unit.com EMail:cadserv21@hotmail. see the Product Manual Installation and Commissioning. type. polarity.Technical specification Power on sequence EM stop sequence Main start sequence Program start sequence Program stop sequence Change program sequence Working space External axes Brake delay time I/O signal Serial communication Action taken when the power is switched on Action taken at an emergency stop Action taken when the program is starting from the beginning Action taken at program start Action taken at program stop Action taken when a new program is loaded Working space limitations Number.039 -0 H8 0. I/O mapping.25 (2x) View from the bottom of the base Figure 15 Hole configuration (dimensions in mm). Endurance load in operation IRB 2400L Force xy ±1700 N Force z floor mounting +4100 ±1100 N Force z inverted mounting -4100 ±1100 N Torque xy Torque z IRB 2400/10 IRB 2400/16 ±3000 Nm ±450 Nm Max. cross connections.comOS 3. mechanical units Time before brakes are engaged Logical names of boards and signals. default value at start up.we will delete 25 . interrupts.cadfamily. A-A www.please inform us. Mounting the manipulator Maximum load in relation to the base coordinate system. load at emergency stop ±2100 N +4100 ±1400 N -4100 ±1400 N ±3400 Nm ±900 Nm ±2600 N +4100 ±1900 N -4100 ±1900 N ±4000 Nm ±900 Nm Force xy ±2000 N Force z floor mounting +4100 ±1400 N Force z inverted mounting -4100 ±1400 N Torque xy Torque z X B ±3400 Nm ±550 Nm Z = centre line axis 1 280 48 B D=18.if tort to your rights. scaling.5 210 Z A A The same dimensions 260 260 Y D=18. com EMail:[email protected] tort to your rights. www.012 kgm2 Figure 16 Maximum weight permitted for load mounting on the mounting flange at different positions (centre of gravity).we will delete .please inform us.com 26 Product Specification IRB 2400 M98A/BaseWare OS 3.Technical specification Load diagrams Z (mm) 600 IRB 2400L Nominal performance 500 1 kg 400 1.1 The document is for study only.5 kg 300 2 kg 200 3 kg 4 kg 5 kg 100 L (mm) 65 100 200 300 400 Z = see the above diagram and the coordinate system in Figure 9 L = distance in X-Y plane from Z-axis to the centre of gravity J = maximum own moment of inertia on the total handling weight = ≤ 0.cadfamily. www.if tort to your rights.012 kgm2 Figure 17 Maximum weight permitted for load mounting on the mounting flange at different positions (centre of gravity).cadfamily.Technical specification Z (mm) 600 IRB 2400L Reduced performance 1 kg 500 400 1.we will delete 27 .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.comOS 3.please inform us.com EMail:[email protected] kg 2 kg 300 3 kg 200 4 kg 5 kg 6 kg 7 kg 100 L (mm) 65 100 200 300 400 Z = see the above diagram and the coordinate system in Figure 9 L = distance in X-Y plane from Z-axis to the centre of gravity J = maximum own moment of inertia on the total handling weight = ≤ 0. www.com EMail:[email protected] kgm2 Figure 18 Maximum weight permitted for load mounting on the mounting flange at different positions (centre of gravity).1 The document is for study only.Technical specification IRB 2400/10 Z (mm) 200 6 kg 150 8 kg 100 10 kg 12 kg 50 L (mm) 100 85 150 200 Z = see the above diagram and the coordinate system in Figure 9 L = distance in X-Y plane from Z-axis to the centre of gravity J = maximum own moment of inertia on the total handling weight = ≤ 0.please inform us.we will delete .com 28 Product Specification IRB 2400 M98A/BaseWare OS 3.if tort to your rights.cadfamily. 1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.com EMail:[email protected] 3.please inform us.060 kgm2 Figure 19 Maximum weight permitted for load mounting on the mounting flange at different positions (centre of gravity).we will delete 29 .Technical specification IRB 2400/16 Z (mm) 200 10 kg 150 12 kg 14 kg 16 kg 100 50 L (mm) 100 85 150 200 Z = see the above diagram and the coordinate system in Figure 9 L = distance in X-Y plane from Z-axis to the centre of gravity J = maximum own moment of inertia on the total handling weight = ≤ 0.if tort to your rights. www. 35 kg total 38o B-B Figure 20 The shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm).cadfamily.Technical specification Mounting equipment The robot is supplied with tapped holes on the upper arm and on the base for mounting extra equipment. 10kg 400 M8 (2x) Depth 14 135 150 D M5 (2x) Depth 9 67 D Max.1 The document is for study only. 1kg 30 170 37 37 62 70 (2x) D=200 400 470 A-A C L D-D M8 (3x) R=77 Depth 16 120o (3x) C 150 D=50 M8 (3x) R=92 Depth 16 B 38o 120o (3x) B C C-C Max.if tort to your rights. IRB 2400L A 300 A Max.com EMail:cadserv21@hotmail. www.we will delete .please inform us.com 30 Product Specification IRB 2400 M98A/BaseWare OS 3. 2kg 90 200 A-A M8 (3x) R=77 Depth 16 120o (3x) Max.com EMail:[email protected] Product Specification IRB 2400 M98A/BaseWare The document is for study only. 35 kg total 38o B-B Figure 21 The shaded area indicates the permitted positions (centre of gravity) for any extra equipment mounted in the holes (dimensions in mm).if tort to your rights.Technical specification IRB 2400/10 IRB 2400/16 A 300 25 400 M6 (2x) M8 (3x) Depth of thread 14 65 177 70 35 110 A M5 (2x) 300 450 100 D=240 22 78 43 Max.please inform us. 10kg C 150 D=50 M8 (3x) R=92 Depth 16 B 38o 120o (3x) B C C-C Max.comOS 3.cadfamily. www.we will delete 31 . 046 h8 D=50 +0 -0.039 h8 .we will delete +0 D=63 -0.012 -0 H7 B ∅ 0.Technical specification IRB 2400L A 45 o D=6 +0.please inform us.012 H7.if tort to your rights. mounting flange (dimensions in mm).039H8 -0 0.05 9 H8 B M6 (4x) R=20 +0.1 The document is for study only.05 B M6 (6x) 60 o 10 R=25 A 7 A-A Figure 22 The mechanical interface. www.com EMail:[email protected] +0.cadfamily.027 D=25 -0 A 90o (4x) 6 A-A IRB 2400/10 IRB 2400/16 A 30 5x o D=6 -0 +0.com 32 Product Specification IRB 2400 M98A/BaseWare OS 3. depth min 8 B D=31. then execute one instruction IF If a condition is met.5 Programming The programming language . A subset of instructions to suit the needs of a particular installation.comOS 3.. inputs/outputs etc. can be installed in pick lists.if tort to your rights.global or local data and routines.extensive program flow control .interrupt handling .hierarchial and modular structure .cadfamily.arithmetic and logical expressions .we will delete 33 .functions and procedures . including structured and array types . . New instructions can easily be made by defining macros consisting of a sequence of standard instructions. Note that the list below only cover BaseWare OS.Technical specification 3. www.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.data typing. . see Product Specification RobotWare. then execute a sequence of instructions label Line name (used together with GOTO) TEST Depending on the value of an expression .user defined names on variables.RAPID .please inform us.backward execution handler The available sets of instructions/functions are given below.user defined instructions . For instructions and functions associated with optional software.is a high-level application-oriented programming language and includes the following functionality: . or the experience of the programmer. Miscellaneous := WaitTime WaitUntil comment OpMode RunMode Dim Present Load UnLoad Assigns a value Waits a given amount of time Waits until a condition is met Inserts comments into the program Reads the current operating mode Reads the current program execution mode Gets the size of an array Tests if an optional parameter is used Loads a program module during execution Deletes a program module during execution To control the program flow ProcCall Calls a new procedure CallByVar Calls a procedure by a variable RETURN Finishes execution of a routine FOR Repeats a given number of times GOTO Goes to (jumps to) a new instruction Compact IF If a condition is met. routines.error handling .com EMail:cadserv21@hotmail.. we will delete .com 34 Product Specification IRB 2400 M98A/BaseWare OS 3.cadfamily.if tort to your rights.please inform us.Technical specification WHILE Stop EXIT Break Motion settings AccSet ConfJ ConfL VelSet GripLoad SingArea PDispOn PDispSet DefFrame DefDFrame EOffsOn EOffsSet ORobT SoftAct TuneServo Motion MoveC MoveJ MoveL MoveAbsJ MoveXDO SearchC SearchL ActUnit DeactUnit Offs RelTool MirPos CRobT CJointT CPos CTool CWObj StopMove StartMove Repeats as long as . Stops execution Stops execution when a restart is not allowed Stops execution temporarily Reduces the acceleration Controls the robot configuration during joint movement Monitors the robot configuration during linear movement Changes the programmed velocity Defines the payload Defines the interpolation method through singular points Activates program displacement Activates program displacement by specifying a value Defines a program displacement automatically Defines a displacement frame Activates an offset for an external axis Activates an offset for an external axis using a value Removes a program displacement from a position Activates soft servo for a robot axis Tunes the servo Moves the TCP circularly Moves the robot by joint movement Moves the TCP linearly Moves the robot to an absolute joint position Moves the robot and set an output in the end position Searches during circular movement Searches during linear movement Activates an external mechanical unit Deactivates an external mechanical unit Displaces a position Displaces a position expressed in the tool coordinate system Mirrors a position Reads current robot position (the complete robtarget) Reads the current joint angles Reads the current position (pos data) Reads the current tool data Reads the current work object data Stops robot motion Restarts robot motion Input and output signals InvertDO Inverts the value of a digital output signal PulseDO Generates a pulse on a digital output signal Reset Sets a digital output signal to 0 Set Sets a digital output signal to 1 SetAO Sets the value of an analog output signal SetDO Sets the value of a digital output signal after a defined time SetGO Sets the value of a group of digital output signals WaitDI Waits until a digital input is set WaitDO Waits until a digital output is set AInput Reads the value of an analog input signal DInput Reads the value of a digital input signal www.1 The document is for study only.com EMail:cadserv21@hotmail... Technical specification DOutput GInput GOutput TestDI IODisable IOEnable Interrupts ISignalDI ISignalDO ITimer IDelete ISleep IWatch IDisable IEnable CONNECT Error Recovery EXIT RAISE RETRY TRYNEXT RETURN Communication TPErase TPWrite TPReadFK TPReadNum ErrWrite System & Time ClkReset ClkStart ClkStop ClkRead CDate CTime GetTime Mathematics Add Clear Decr Incr Abs Sqrt Exp Pow ACos ASin ATan/ATan2 Cos Sin Reads the value of a digital output signal Reads the value of a group of digital input signals Reads the value of a group of digital output signals Tests if a digital input signal is set Disables an I/O module Enables an I/O module Orders interrupts from a digital input signal Orders interrupts from a digital output signal Orders a timed interrupt Cancels an interrupt Deactivates an interrupt Activates an interrupt Disables interrupts Enables interrupts Connects an interrupt to a trap routine Terminates program execution Calls an error handler Restarts following an error Skips the instruction that has caused the error Returns to the routine that called the current routine Erases text printed on the teach pendant Writes on the teach pendant Reads function keys Reads a number from the teach pendant Stores an error message in the error log Resets a clock used for timing Starts a clock used for timing Stops a clock used for timing Reads a clock used for timing Reads the current date as a string Reads the current time as a string Gets the current time as a numeric value Adds a numeric value Clears the value Decrements by 1 Increments by 1 Calculates the absolute value Calculates the square root Calculates the exponential value with the base “e” Calculates the exponential value with an arbitrary base Calculates the arc cosine value Calculates the arc sine value Calculates the arc tangent value Calculates the cosine value Calculates the sine value 35 www.com EMail:[email protected] Product Specification IRB 2400 M98A/BaseWare The document is for study only.we will delete .cadfamily.if tort to your rights.comOS 3.please inform us. Type of diskette: 3.44 MB Depending on type of instruction.we will delete .5 MB2) 6. Programs and all user-defined data are stored in ASCII format. Each battery has a capacity of 5-6 months power off time (depending of memory board size). www. i.Technical specification Tan EulerZYX OrientZYX PoseInv PoseMult PoseVect Round Trunc Text strings NumToStr StrFind StrLen StrMap StrMatch StrMemb StrOrder StrPart StrToVal ValToStr Calculates the tangent value Calculates Euler angles from an orientation Calculates the orientation from Euler angles Inverts a pose Multiplies a pose Multiplies a pose and a vector Rounds a numeric value Truncates a numeric value Converts numeric value to string Searches for a character in a string Gets the string length Maps a string Searches for a pattern in a string Checks if a character is a member of a set Checks if strings are ordered Gets a part of a string Converts a string to a numeric value Converts a value to a string For more information on the programming language. 3) Requires approx.5 MB 4.e. Memory backup The RAM memory is backed up by two Lithium batteries.cadfamily.if tort to your rights.5” 1.please inform us.com EMail:[email protected] The document is for study only. Memory Memory size Program memory: Standard Extended memory 8 MB Mass storage3) : RAM memory Standard Extended 8 MB Diskette 1) 2) Instructions1) 7500 18000 3000 31000 15000 2. 1 MB mass memory can store 3 MB of RAPID instructions.44 MB (HD) MS DOS format. 3 times less space than in the program memory.0 MB2) 0. Some software options reduce the program memory. See Product Specification RobotWare. A warning is given at power on when one of the batteries is empty.com 36 Product Specification IRB 2400 M98A/BaseWare OS 3. see RAPID Reference Manual.0 MB 1. Reduce the velocity temporarily .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.we will delete 37 . The maintenance intervals depends on the use of the robot.comOS 3.6 Automatic Operation The following production window commands are available: . www.Displace a position.if tort to your rights. For detailed information on maintenance procedures.Execute instruction-by-instruction (forward/backward) .7 Maintenance and Troubleshooting The following maintenance is required: .com EMail:[email protected] oil in the wrist after the first year and then every 5th year.Changing filter for the drive system cooling every year.Technical specification 3. .Start the program . see Maintenance section in the Product Manual. also during program execution (can be blocked) 3.Display program-controlled comments (which tell the operator what is happening) .Changing batteries every 3rd year. .Load/select the program .cadfamily.please inform us. x 970 404 602 1577 400 -1611 -115 z 1620 2298 745 -246 -403 623 1088 Angle (degrees) pos. www. 0 1 2 3 4 5 6 axis 2 0 0 0 110 110 -100 -100 axis 3 0 -60 65 -60 24.8 Robot Motion IRB 2400L The working area is the same for both floor and inverted mounting Type of motion Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion 3421 Wrist centre Pos 0 Axis 4 Axis 3 1702 + + Pos 6 Axis 2 + R= Range of movement +180o +110o +65o +185o +115o +400o to to to to to to -180o -100o -60o -185o -115o -400o (Unlimited as optional) Z Pos 1 + Axis 5 521 + Axis 6 2885 Pos 2 Pos 5 X Axis 1 100 Pos 4 Pos 3 560 1810 R= 570 00 =4 R Positions at wrist centre (mm) pos.com EMail:[email protected] specification 3.please inform us.5 -60 65 Pos 4 0 1 2 3 4 5 6 Figure 23 The extreme positions of the robot arm (dimensions in mm).if tort to your rights.com 38 Product Specification IRB 2400 M98A/BaseWare OS 3.cadfamily.1 The document is for study only.we will delete . 3 -60 65 R= 570 Pos 4 Figure 24 The extreme positions of the robot arm (dimensions in mm).if tort to your rights.cadfamily. IRB 2400/16 The working area is the same for both floor and inverted mounting Type of motion Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Rotation motion Arm motion Arm motion Wrist motion Bend motion Turn motion 2900 Range of movement +180o +110o +65o +200o +120o +400o to to to to to to -180o -100o -60o -200o (Unlimited as optional) -120o -400o (Unlimited as optional) Pos 1 Z Axis 4 Axis 3 1441 + + Pos 6 Axis 2 Pos 5 + 448 R= Wrist centre Pos 0 + + Axis 5 Axis 6 2458 Pos 2 Axis 1 100 Pos 4 Pos 3 393 X 1550 00 =4 R Positions at wrist centre (mm) pos.comOS 3.we will delete 39 .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. www. 0 1 2 3 4 5 6 x 855 360 541 1351 400 -1350 -53 z 1455 2041 693 -118 -302 624 1036 Angle (degrees) pos.please inform us.com EMail:cadserv21@hotmail. 0 1 2 3 4 5 6 axis 2 0 0 0 110 110 -100 -100 axis 3 0 -60 65 -60 18.Technical specification IRB 2400/10. If guaranteed values are required.com 40 Product Specification IRB 2400 M98A/BaseWare OS 3.01o on each axis.please inform us. Unidirectional pose repeatability: RP = 0.6 sec. (on 35 mm linear path) 0.4 .0. to within 0.if tort to your rights.35 sec. www.06 mm Linear path accuracy: AT = 0. Velocity Versions: Axis no.0 mm Linear path repeatability: RT = 0.cadfamily.45 .1.0.2 .1 The document is for study only.Technical specification Performance according to ISO 9283 At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axes in motion.25 mm Minimum positioning time.2 mm of the position: 0. 1 2 3 4 5 6 IRB 2400L 150o/s 150o/s 150o/s 360o/s 360o/s 450o/s IRB 2400/10 150o/s 150o/s 150o/s 360o/s 360o/s 450o/s IRB 2400/16 150o/s 150o/s 150o/s 360o/s 360o/s 450o/s There is a supervision to prevent overheating in applications with intensive and frequent movements.0. please contact your nearest ABB Flexible Automation Centre. 0.com EMail:[email protected] will delete . (on 350 mm linear path) The above values are the range of average test-results from a number of robots. Resolution Approx.14 . When more than two external axes are used. www.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. see the Product Manual Installation and Commissioning. SMB Not supplied on delivery Alt.cadfamily. Optional SMB Not supplied on delivery Figure 25 Outline diagram.comOS 3. The SMB is located close to the motor(s) according to Figure 25. the drive units for external axis 3 and upwards must be placed in a separate cabinet according to Figure 25.0 V/4 kHz Absolute position is accomplished by battery-backed resolver revolution counters in the serial measurement board (SMB).Technical specification 3.we will delete 41 .9 External Axes An external axis is an AC motor (IRB motor type or similar) controlled via a drive unit mounted in the robot cabinet or in a separate enclosure. See Specification of Variants and Options. Resolver Resolver supply Connected directly to motor shaft Transmitter type resolver Voltage ratio 2:1 (rotor: stator) 5. or inside the cabinet.please inform us.com EMail:cadserv21@hotmail. For more information on how to install an external axis. external axes.if tort to your rights. “Screw terminals” on the I/O units .2 500 Kbit/s * Max. No. 20x 25x 22x 23x 26x 281 284-285 286-287 16 16 1282 642 1282 100 1 16 16 128 64 128 100 30 30 In 16 16 Out 16 16 4 3 2 1 Voltage inputs Analog Voltage output Current output Power supply Internal/External1 Internal/External Internal Internal/External1 Internal/External1 1. To calculate the number of logical signals. group I/O. A non physical I/O unit can be used to form cross connections and logical conditions without physical wiring. 3. analog and digital including field buses) Max. Digital Type of unit Digital I/O 24 VDC Digital I/O 120 VAC Analog I/O AD Combi I/O Relay I/O Allen-Bradley Remote I/O Slave Interbus-S Slave Profibus DP Slave Simulated I/O3 Encoder interface unit4 288-289 Option no. total cable length Cable type (not included) Data rate (fixed) 20 (including SIM units) 100 m According to DeviceNet specification release 1.10 Inputs and Outputs Types of connection The following types of connection are available: . The following table shows the maximum number of physical signals that can be used on each unit. www.cadfamily. total no of units* Max. Dedicated for conveyor tracking only.Serial interface for distributed I/O units . Some ProcessWares include SIM unit.please inform us. 2.com EMail:[email protected] will delete . each group having 8 inputs or outputs. I/O units Several I/O units can be used. of signals are to be configured. four units can be mounted inside the cabinet. 4.if tort to your rights. see Chapter 4: Specification of Variants and Options. The digital signals are supplied in groups.1 The document is for study only.Technical specification 3. Distributed I/O The total number of logical signals is 512 (inputs or outputs. add 2 status signals for RIO unit and 1 for Interbus-S and Profibus DP.Air and signal connections to upper arm For more detailed information.com 42 Product Specification IRB 2400 M98A/BaseWare OS 3. short-circuit protected.com EMail:[email protected] specification Signal data Permitted customer 24 V DC load Digital inputs 24 V DC (options 201-208. 231-238) 24 V DC Optically-isolated. supply polarity protection Voltage supply 19 to 35 V Rated voltage 24 V DC Output current: max.we will delete 43 .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. 231-238. 500 V Time delays: hardware ≤ 1 ms software ≤ 2 ms Time variations: ± 2 ms Relay outputs (options 261-268) Single pole relays with one male contact (normally open) Rated voltage: 24 V DC. 2 A Potential difference: max. 261-268) Optically-isolated Rated voltage: Logical voltage levels: “1” “0” Input current at rated input voltage: Potential difference: max.5 A Potential difference: max. 500V Time intervals: hardware (set signal) typical 13 ms hardware (reset signal) typical 8 ms software ≤ 4 ms Digital inputs 120 V AC (options 251-258) Optically isolated Rated voltage Input voltage range: “1” Input voltage range: “0” Input current (typical): Time intervals: hardware software 120 V AC 90 to 140 V AC 0 to 45 V AC 7. 120 VAC Voltage range: 19 to 35 V DC 24 to 140 V AC Output current: max.if tort to your rights. Time delays: hardware software Time variations: max. 6 A 24 V DC 15 to 35 V -35 to 5 V 6 mA 500 V 5−15 ms ≤ 3 ms ± 2 ms Digital outputs (options 201-208.comOS 3.5 mA ≤ 20 ms ≤ 4 ms www. 0.please inform us.cadfamily. 5 V Time intervals: hardware ≤ 12 ms software ≤ 4 ms Analog inputs (options 221-228) Voltage Input voltage: +10 V Input impedance: >1 Mohm Resolution: 0.0 ms ≤ 4 ms For connection of extra equipment on the manipulator. 30mA Voltage range: 24 to 140 V AC Potential difference: max. 8 bar.2% of input signal Analog outputs (option 221-228) Voltage Output voltage: Load impedance: Resolution: Current Output current: Load impedance: Resolution: Accuracy: +10 V 2 kohm 2. one Burndy UTG 014 12SHT connector and one Burndy UTG 018 23SHT connector on the rear part of the upper arm. 2A/channel. 10 A 16 channels (56 A in 20 ms) min.1 The document is for study only.44 mV (12 bits) 4-20 mA 800 ohm 4.88 µA (12 bits) +0. voltage spike protection Rated voltage 120 V AC Output current: max. 1.61 mV (14 bits) Accuracy: +0. 500 V Off state leakage current: max. Analog outputs (option 231-238) Output voltage (galvanically isolated): Load impedance: min. there are cables integrated into the manipulator’s cabling.cadfamily. 250 mA 250 V. 1A/channel. 2mA rms On state voltage drop: max. There is an inlet (R1/4”) at the base and an outlet (R1/4”) on the rear part of the upper arm.please inform us.44 mV (12 bits) ±25 mV ±0.Technical specification Digital outputs 120 V AC (options 251-258) Optically isolated. A hose for compressed air is also integrated into the manipulator. min. inner hose diameter 8 mm www.5% of output voltage max. 500 V ≤ 2. 2 A Max.if tort to your rights.2% of output signal min. Resolution: Accuracy: Potential difference: Time intervals: hardware software: Signal connections on robot arm 0 to +10 V 2 kohm 2.we will delete .com 44 Product Specification IRB 2400 M98A/BaseWare OS 3. 12 A 16 channels or max.com EMail:cadserv21@hotmail. Signals Power Air 23 10 1 50 V. Digital outputs Motors on/off Executes program Error Automatic mode Emergency stop Restart not possible Restart not successful Run chain closed Motors on/off Starts program from where it is Motors on and program start Starts program from the beginning Stops program Stops program when the program cycle is ready Stops program after current instruction Executes “trap routine” without affecting status of stopped regular program1 Loads and starts program from the beginning1 Resets error Resets emergency stop System reset Synchronizes external axes TCP speed signal Digital inputs Analog output 1.Technical specification System signals Signals can be assigned to special system functions.if tort to your rights. see User’s Guide .System Parameters. www.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. Program can be decided when configuring the robot.we will delete 45 .com EMail:cadserv21@hotmail. Several signals can be given the same functionality. For more information on system signals.cadfamily.comOS 3.please inform us. The serial channels can be used at speeds of 300 to 19200 bit/s (max. For high speed and/or network communication.which can be used to communicate point to point with printers. Character-based or binary information can be transferred using RAPID instructions. This requires either the option FactoryWare Interface or RAP Communication.we will delete .if tort to your rights. a Robot Application Protocol (RAP) can be used.1 The document is for study only.11 Communication The robot has two serial channels . 1 channel with speed 19200 bit/s). In addition to the physical channels. computers and other equipment (see Figure 26). This requires the option Advanced functions. Figure 26 Serial point-to-point communication. www.one RS232 and one RS422 Full duplex . the robot can be equipped with Ethernet interface (see Figure 27).cadfamily. see Product Specification RobotWare. Transmission rate is 10Mbit/s.com EMail:[email protected] specification 3. see Product Specification RobotWare.com 46 Product Specification IRB 2400 M98A/BaseWare OS 3.please inform us. Figure 27 Serial network communication. terminals. Degree of protection as in chapter 3. The manipulator is finished with a special coating.4.10. Specifies the max. It can easily be changed without additional parts. Not possible on IRB 2400L.Handling capacity Application: Reach: Handling capacity: F Robot adapted for foundry environments.if tort to your rights.we will delete 47 . The same numbers are used here as in the Specification form. Specifies the nominal handling capacity. Note Options marked with * are inconsistent with UL/UR approval.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. www.please inform us. 041 Integrated hose and cables for connection of extra equipment on the manipulator to the rear part of the upper arm.cadfamily.Specification of Variants and Options 4 Specification of Variants and Options The different variants and options for the IRB 2400 are described below. see Product Specification RobotWare.comOS 3.com EMail:cadserv21@hotmail. 043 Hose and cables for connection of extra equipment are extended to the wrist on the outside of the upper arm. MOUNTING POSITION This choice specifies the configuration the robot will be delivered in. For software options. reach at the wrist centre. 02x Floor mounted 02y Hanging APPLICATION INTERFACE For more details see chapter 3. 1 MANIPULATOR VARIANTS 021 022 023 024 025 026 IRB 2400L IRB 2400FL IRB 2400/10 IRB 2400F/10 IRB 2400/16 IRB 2400F/16 IRB 2400 Application / Reach . option 021 and 022. Phoenix MSTB 2.08. The cables connected to the Burndy connector must have a tightly closing cover with dimension according to Figure 28. (Only together with options 641-644) External connection The signals are connected directly to the manipulator base to one 40-pins Harting connector. See Figure 38. Internal connection 67A.08.com 48 Product Specification IRB 2400 M98A/BaseWare OS 3. (Only together with options 651-656) Not supplied on delivery Cover D=7 (2x) 40 74 86 Figure 28 Cover for internal connection of signals.com EMail:cadserv21@hotmail. 671-674 MOUNTING OF TOOL SYSTEM ON ROBOT BEFORE DELIVERY 919 Mounting of extra equipment ordered from ABB Flexible Automation/Dpt U. If 43x If 043 If 67A-67D. www.we will delete .5/12-ST-5.The signals are connected to 12-pole screw 674 terminals. 045 Internal connection The signals are connected directly inside the manipulator base to one 24-pins rectangular Burndy connector and one 12-pins rectangular Burndy connector.if tort to your rights. See Figure 38. Phoenix MSTB 2.5/12-ST-5. External connection 671.The signals are connected to 12-pole screw 67D terminals.please inform us. options 641-644 and 651-656.1 The document is for study only. inside the controller.Specification of Variants and Options CONNECTION OF SIGNALS Internal or external connection is ordered by the choice of manipulator cable.cadfamily. inside the controller. 1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. o 50 The stops can be mounted within the area o to 140o. 2 and 3 can be restricted by extra mechanical stops. A design with two stationary or 1. Switches axis 1 (see Figure 29) 081 One switch 082 Two switches 083 Three switches The second switch The third switch Controller The first switch Controller Controller Figure 29 Connections of the switches 084 Two switches. POSITION SWITCH Switches indicating the position of axis 1.comOS 3. 071. 074 in the controller.please inform us. Connection of signals Controller Figure 30 Connections of the switches.com EMail:cadserv21@hotmail. The lamp is active in MOTORS ON mode. stationary (see Figure 30) The two switches divide the working area of axis 1 into two fixed working zones. this option allows access to one working zone at the same time as the robot is working in the other one.we will delete 49 .cadfamily. Together with external safety arrangement. 175o each. The switches are manufactured by Telemecanique or Burnstein. and of type forced disconnect. WORKING RANGE LIMIT To increase the safety of the robot.The signals are connected to 12-pole screw terminals.08. Phoenix MSTB 2. The safety lamp is required on a UL/UR approved robot. approx. 2 or 3 adjustable switches is available. Note The switches are not recommended to be used in severe environment with sand or chips. from 50 140o 50o 140o Figure 31 www. axis 1. See Figure 31.5/12-ST-5. the working range of axes 1.if tort to your rights. 621 Axis 1 Two extra stops for restricting the working range.Specification of Variants and Options SAFETY LAMP 691 A safety lamp with an orange fixed light can be mounted on the manipulator. This option is inconsistent with UL approval (option 695 UL Listed). has tested and examined the finished complete product. 115 With cabinet extension. 80 o 20o 40o 50o 70o Figure 32 623 Axis 3 Equipment for electrically restricting the working range in increments of 5o.com EMail:cadserv21@hotmail. Figure 32 illustrates the mounting positions of the stops.cadfamily. manipulator and controller. This option is inconsistent with UL approval (option 695 UL Listed). The height of the cover is 250 mm. and determined that they fulfil the stipulated safety standards. Option 112 Standard cabinet without upper cover can not be UL Listed at delivery. A cabinet extension is mounted on top of the standard cabinet. certificate on component level. Some options marked with * are inconstistent with UL Listed. Underwriters Laboratories Inc. 695 UL Listed. To be used when cabinet extension is mounted on top of the cabinet after delivery.we will delete . 696 UR Recognized. it may be ordered as UL Recognized.e. has tested and examined the components in the product.if tort to your rights. manipulator and controller. i. certificate on product level. Underwriters Laboratories Inc. 2 SAFETY STANDARDS UNDERWRITERS LABORATORY Option 691 Safety lamp is included on UL and UR robots. 114 With extended cover 250 mm. and determined that the product fulfils the stipulated safety standards. 112 Standard cabinet without upper cover. which increases the available space for external equipment that can be mounted inside the cabinet. There is a mounting plate www. 3 CONTROL SYSTEM CABINET 111 Standard cabinet (with upper cover).please inform us.com 50 Product Specification IRB 2400 M98A/BaseWare OS 3.Specification of Variants and Options 622 Axis 2 Stop lugs for restricting the working range. 800 mm.1 The document is for study only. we will delete 51 .com EMail:cadserv21@hotmail. without Castor wheels. 183 External. 181 Standard.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. 182 External. including flange.e. on the front of the cabinet.cadfamily. (See Figure 35) www. Shaded area 40x40 (four corners) not available for mounting 705 730 Figure 33 Mounting plate for mounting of equipment (dimensions in mm). OPERATOR’S PANEL The operator’s panel and teach pendant holder can be installed in different ways.. External enclosure is not supplied. is supplied. mounted in a box. This option cannot be combined with option 142.e.if tort to your rights.comOS 3. sealing strips. i. i. etc.e. The upper part of the standard cabinet is therefore accessible. CABINET TYPE 121 Standard. 125 ARCITEC A special designed cabinet dedicated for SEFAW arc welding system ARCITEC Requires option 111 or 114 and 131. screws. This option is inconsistent with UL approval (option 695 UL Listed). This option is inconsistent with UL approval (option 695 UL Listed). All necessary cabling. 145 or 146 and 147 or 149. (See Figure 33).please inform us. 122 Cabinet on Castor wheels. The cabinet extension is opened via a front door and it has no floor. in a separate operator’s unit. (See Figure 34). connectors.Specification of Variants and Options inside. i. Specification of Variants and Options M4 (x4) M8 (x4) 45 o 196 Required depth 200 mm 193 223 180 224 240 70 62 96 Holes for flange 140 184 External panel enclosure (not supplied) 200 Holes for operator’s panel Teach pendant connection Holes for teach pendant holder 90 Connection to the controller 5 (x2) 155 Figure 34 Required preparation of external panel enclosure (all dimensions in mm).1 The document is for study only.com 52 Product Specification IRB 2400 M98A/BaseWare OS 3.cadfamily. M5 (x4) for fastening of box 337 Connection flange 370 Figure 35 Operator’s panel mounted in a box (all dimensions in mm).please inform us. www.if tort to your rights.we will delete .com EMail:cadserv21@hotmail. 151174 Voltage 200 V 220 V 400 V 440 V Voltage Voltage 400 V 440 V 475 V 500 V 475 V 500 V 525 V 600 V www. MAINS FILTER (EU Electromagnetic compability) The mains filter reduces the emission of radio frequency on the incoming power.cadfamily. (The option number is depending on the transformer).if tort to your rights. to levels below requirements in the Machinery Directive 89/392/EEC.comOS 3. A voltage fluctuation of +10% to -15% is permissible in each connection. 3 modes: manual. For installations in countries not affected by this directive.Specification of Variants and Options EXTERNAL CABLE LENGT (for external panel) 185 15 m 186 22 m 187 30 m OPERATING MODE SELECTOR 193 Standard.we will delete 53 . the filter can be excluded. At higher temperatures a cooling device for the drive is necessary to ensure good functionality. DISK DRIVE COOLING 472 The disk drive normally works well at temperatures up to +40oC (104oF).com EMail:cadserv21@hotmail. 177-179 Mains filter MAINS VOLTAGE The robot can be connected to a rated voltage of between 200 V and 600 V.please inform us. manual full speed and automatic.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. 2 modes: manual and automatic 191* Standard. The disk drive will not deteriorate at higher temperatures but there will be an increase in the number of reading/writing problems as the temperature increases. 3-phase and protective earthing. 134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640. 600 V. for Arcitec 146 Rotary switch 80 A with door interlock. 136* 32 A. 6p + PE (see Figure 37). MAINS SWITCH 141* Rotary switch in accordance with the standard in section 3. 131 Cable gland for inside connection.1 The document is for study only. the female connector (cable part) is included. Figure 36 CEE male connector.please inform us.we will delete . Circuit breaker approved in accordance with IEC 898. Diameter of cable: 11-12 mm. If option 132-133 is chosen. for Arcitec 147/149 Circuit breaker for rotary switch.Specification of Variants and Options CONNECTION OF MAINS The power is connected either inside the cabinet or to a connector on the cabinet’s left-hand side. www.com 54 Product Specification IRB 2400 M98A/BaseWare OS 3. (The option number is depending on the transformer). 3p + PE (see Figure 36). A 16 A (147) or 25 A (149) circuit breaker for short circuit protection of main cables in the cabinet. 142 Rotary switch with door interlock. 380-415 V. VDE 0660. 145* Rotary switch 80 A. Figure 37 DIN male connector.2.2 and IEC 337-1.com EMail:cadserv21@hotmail. 3p + N + PE (see Figure 36). Includes door interlock. 133* 32 A. VDE 0113.if tort to your rights. 143 Flange disconnect in accordance with the standard in section 3. The cable is not supplied.cadfamily. 35 A. 380-415 V. 221-224.4 safety signals X5 X8 X6 CONTROL PANEL XT5. CABINET I/O MODULES 201-208 Digital 24 VDC I/O: 16 inputs/16 outputs.com EMail:cadserv21@hotmail. customer power XT8. 261-264) The signals are connected directly to screw terminals on the I/O units in the upper part of the cabinet (see Figure 38).please inform us. Connection of I/O: 301 Internal connection (options 201-204.cadfamily. see Technical Specification 3. Relay outputs to be used when more current or voltage is required from the digital outputs. 251-254.comOS 3. X1 (SIO1) X2 (SIO2) I/O units (x4) X10 (CAN3) X16 (CAN2) Backplane Panel unit WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN MS NS ES1 ES2 GS1 GS2 AS1 AS2 X1 .10.Specification of Variants and Options I/O AND COMMUNICATION The standard cabinet can be equipped with up to four I/O units. www. 231-238 AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 251-258 Digital 120 VAC I/O 16 inputs/16 outputs. 231-234.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. customer signals XT6. 221-228 Analog I/O: 4 inputs/4 outputs. The inputs are not separated by relays. position switch X9 (CAN1) XT21 (115/230 V ACsupply) XT31 (24V supply) Figure 38 I/O unit and screw terminal locations.if tort to your rights. 261-268 Digital I/O with relay outputs: 16 inputs/16 outputs. For more details. Note The use of I/O units and field buses can be limited because of CPU overload in the controller during motions.we will delete 55 . but no cabling. is the function whereby the robot follows a work object which is mounted on a moving conveyor.08). or Line Tracking. The signals are connected directly to the InterBus-S-slave unit (two 9-pole D-sub) in the upper part of the cabinet.9. 284/285 InterBus-S Slave Up to 64 digital inputs and 64 digital outputs per unit. ADDITIONAL UNITS I/O units can be delivered separately.Specification of Variants and Options FIELD BUSES MOUNTED IN CABINET For more details. CONNECTION OF SAFETY SIGNALS 381 Internal The signals are connected directly to screw terminals (X1-X4) in the upper part of the cabinet (see Figure 38). can be transferred serially to a PLC equipped with an InterBus-S interface. in groups of 16. see Figure 38) in the upper part of the cabinet. Connectors to the I/O units and a connector to the cabinet (Phoenix MSTB 2. in groups of 32. is included. and to a 5-pole screw connector.if tort to your rights. can be transferred serially to a PLC equipped with a Profibus DP interface. see Technical Specification 3. The unit reduces the number of I/O units that can be mounted in cabinet by one. in groups of 16. 286/287 Profibus DP Slave Up to 128 digital inputs and 128 digital outputs per unit. and to a 5-pole screw connector.5/xx-ST-5. see Technical Specification 3. The signals are connected directly to the Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet. The unit reduces the number of I/ O units that can be mounted in cabinet by one.please inform us. 288/289 Encoder interface unit for conveyor tracking Conveyor Tracking.9 281 Allen-Bradley Remote I/O Slave Up to 128 digital inputs and 128 digital outputs. 68G-H Analog I/O. 68A-F Digital I/O 24 V DC: 16 inputs/16 outputs.we will delete .1 The document is for study only. For more details. Measures according to Figure 39 and Figure 40. The encoder and synchronization switch cables are connected directly to the encoder unit in the upper part of the cabinet (see Figure 38). 68I-L AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).cadfamily. Screw connector is included. www. For more information see Product Specification RobotWare.com EMail:cadserv21@hotmail. The field bus cables are connected directly to the screw terminals on the A-B RIO unit in the upper part of the cabinet (see Figure 38). The units can then be mounted outside the cabinet or in the cabinet extension. The unit reduces the number of I/O units that can be mounted in cabinet by one. can be transferred serially to a PLC equipped with an Allen-Bradley 1771 RIO node adapter.com 56 Product Specification IRB 2400 M98A/BaseWare OS 3. These are connected in a chain to a connector (CAN 3 or CAN 2. 292 EtherNet (see Figure 27). 294 DeviceNet Connection on the left side to a 5-pole connector in accordance with ANSI.please inform us. EN 50022 mounting rail 49 170 115 Figure 40 Dimension for units 67U-Z. Connectors: RJ45 and AUI on the board front.com EMail:cadserv21@hotmail. See Figure 26 and Figure 38. the robot is equipped with one RS232 (SIO 1) and one RS422 (SIO 2) connector inside the cabinet.cadfamily. 68U Allen Bradley Remote I/O 68V-X Interbus-S Slave 68Y-Z Profibus DP Slave 69A-B Encoder interface unit for conveyor tracking EN 50022 mounting rail 195 203 Figure 39 Dimensions for units 68A-T. 68Q-T Digital I/O with relay outputs: 16 inputs/16 outputs.comOS 3. 69A-B.if tort to your rights.Specification of Variants and Options 68M-P Digital I/O 120 V AC: 16 inputs/16 outputs.we will delete 57 . 49 COMMUNICATION As standard. www.1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. The signals are connected to 9-pole D-sub connectors on the backplane. 1 The document is for study only. 398 Prepared for GT No drive units or cables are included.com EMail:cadserv21@hotmail. on the lefthand side of the cabinet. Recommended motor type see Figure 41. www. Recommended motor type see Figure 41. only transformer 7. the total length of cable between the controller and the teach pendant should not exceed 30 m.The motors are connected to a standard industrial 64-pin female connector.2 kVA.Specification of Variants and Options TEACH PENDANT The teach pendant is.e.5 kVA is replaced with 7. (Male connector is also supplied. 394 Drive unit T+GT A combination of 391 and 392. equipped with a sharp and clear display without back lighting. and the DC-link size DC1 is replaced with DC2.) The transformer 4. 395 Drive unit C The drive unit is part of the DC-link.2 kVA and DC link DC2. as standard. 631 With back lighting 632 Without back lighting Extension cable for the teach pendant: 661 10 m This can be connected between the controller and the connector on the teach pendant’s cable.we will delete . in accordance with DIN 43652.cadfamily.if tort to your rights. Recommended motor types see Figure 41. 392 Drive unit GT A separate drive unit including two drives. i. 662 2 x 10 m Teach pendant language: 575 576 577 578 579 580 581 582 583 584 English Swedish German French Spanish Portuguese Danish Italian Dutch Japanese EXTERNAL AXES Drive unit mounted in cabinet The controller is equipped with drives for external axes. Back lighting is available as an option.please inform us. 396 Drive unit C+GT A combination of 395 and 392. A maximum of two extension cables may be used.com 58 Product Specification IRB 2400 M98A/BaseWare OS 3. 391 Drive unit T The drive unit is part of the DC-link. The cables are connected directly to the drive units inside the cabinet via a cable 644 gland on the left-hand side of the controller and to a connector inside the manipulator base. Door interlock.if tort to your rights. M.we will delete 59 . mains connection. 37Q 37V 37X Drive unit ECB. or to a measurement board inside the cabinet. Types: S=small (TN=1. These options are not available for IRB 2400F.5 . M=medium (TN=4 Nm). 386 Serial measurement board inside cabinet Signal interface to external axes with absolute position at power on. Recommended motor types see Figure 41.5 Nm).please inform us.2 kVA. on the left-hand side of the cabinet.7A rms Rated current 20A rms 16A rms 8. Motors from Flexible Automation/System Products. 37N-O Drive unit GT.Specification of Variants and Options EXTERNAL AXES MEASUREMENT BOARD The resolver can either be connected to a serial measurement board outside the controller.com EMail:[email protected] 2.cadfamily. L S. www. an external cabinet can be supplied. for 3 or 6 motors.comOS 3. The resolvers are connected to a standard industrial 64-pin connector in accordance with DIN 43652. or 6 motors. The external cabinet is connected to one Harting connector (cable length 7 m) on the left-hand side of the robot controller. Recommended motor types see Figure 41.SEPARATE CABINET If more external axes than in option 390 are to be used. internal connectors 641.37A rms 6 . M. for 4. M S S 1.5 . Drive unit GT + ECB Drive unit GT + GT + ECB Drive unit data T G E C B Max current 7.5 .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only. mains voltage and mains filter according to the robot controller. The board is located in the cabinet and occupies one I/O unit slot.30A rms 4 . L=large (TN=12 Nm) Figure 41 Motor selecting table. One transformer 7. EQUIPMENT Manipulator cable. L S.11A rms 1. 387 Serial measurement board as separate unit EXTERNAL AXES .4Arms 5A rms 4A rms Motor type1 S. and one mains switch are included. POWER SUPPLY 431 Connection from the main transformer. NFPL 79 for example. 433 Connection before mains switch with an additional transformer for line voltages 400-500 V and with a secondary voltage of 115 V or 230 V. metal braided SERVICE OUTLET Any of the following standard outlets with protective earthing can be chosen for maintenance purposes.we will delete . Note! Connection before mains switch is not in compliance with some national standards. single socket. NFPL 79 for example. www. external connection 651. The computer connection is connected to the RS232 serial channel.com EMail:cadserv21@hotmail. 432 Connection before mains switch without transformer. single socket. Note! Connection before mains switch is not in compliance with some national standards. three-phase with neutral connection and a 230 V service socket. located on the left-hand side of the controller and on the base of the manipulator. 100 W can be installed inside the cabinet).if tort to your rights. single socket.1 The document is for study only.com 60 Product Specification IRB 2400 M98A/BaseWare OS 3. The maximum load permitted is 500 VA (max.cadfamily. 424 120 V in accordance with American standard.please inform us. single socket suitable for Sweden. Harvey Hubble.The cables are connected to 64-pin standard industrial connectors in accordance with 654 DIN 43652. metal braided 656 15 m. 421* 230 V mains outlet in accordance with DIN VDE 0620. 425* Service outlet according to 421 and a computer connection on the front of the cabinet. Note this only applies when the mains voltage is 400 V. 422* 230 V in accordance with French standard.Specification of Variants and Options Manipulator cable. 655 7 m. Germany and other countries. 423* 120 V in accordance with British standard. The voltage is switched on/off by the mains switch on the front of the cabinet. 2A. please inform us.com EMail:[email protected] tort to your rights. EXTRA DOCUMENTATION Product Manuals G11-G13 G21-G23 G31-G33 G41-G43 G51-G53 G61-G63 G71-G73 G81-G83 G91-G93 English Swedish German French Spanish Portuguese Danish Italian Dutch www.cadfamily. the service outlet can be supplied with an earth fault protection which trips at 30 mA earth current.comOS 3.240 V AC. Voltage range: 110 . The earth fault protection is placed next to the service outlet (see Figure 38).we will delete 61 .1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.Specification of Variants and Options 439 Earth fault protection To increase personal safety. cadfamily.we will delete .com EMail:[email protected] inform us.Specification of Variants and Options www.if tort to your rights.1 The document is for study only.com 62 Product Specification IRB 2400 M98A/BaseWare OS 3. 1 Product Specification IRB 2400 M98A/BaseWare The document is for study only.Motor Units www.comOS 3. specially designed for the robot.if tort to your rights.please inform us.cadfamily.Tool System .Track Motion .Accessories 5 Accessories There is a range of tools and equipment available. Software options for robot and PC For more information. Robot Peripherals .com EMail:cadserv21@hotmail. see Product Specification RobotWare.we will delete 63 . please inform us.com EMail:[email protected] will delete .com 64 Product Specification IRB 2400 M98A/BaseWare OS 3.if tort to your rights.1 The document is for study only.Accessories www.cadfamily. ..................... 29 4.......................................................................... 5 2.......................6 PaintWare 3.....3 Robot Documentation..........3 Motion Control ........................................................ 46 5.............2 ArcWare Plus 3................................................................................................................................................ 45 5...................................................................................................................................4 FactoryWare Interface 3.......................................................................... 5 2.................................................1 Available memory. 6 2.......................................................... 22 3...........1.................................... 3 2 BaseWare OS ........................................... 38 4...................................... 42 5 Memory and Documentation ............................... 9 2.....................................3 SpotWare 3............................................. 23 3........... 25 3..............................1.1 ......................................................please inform us..............6 Ethernet Services 3........................................................2 Exception handling ............................ 28 4 ProcessWare........... 24 3............................................ 27 3...............2 Teach Pendant Language ..............................................4 Safety ...............................................7 PalletWare........................... 19 3................1........................................ 29 4............................................ 7 2...............................................we will delete 1 ................................................1 ............................... 10 3 BaseWare Options ...............................com EMail:cadserv21@hotmail.............................................1...........................................5 RAP Communication 3.........................................5 I/O System ....................................................................1................................................1 .......................................1 ................................................................if tort to your rights........................... 11 3.............................................1..............2 Advanced Motion 3................................................8 ScreenViewer 3.........7 Load Identification and Collision Detection 3................................................................... 37 4............ 20 3....4 SpotWare Plus 3.1 Advanced Functions 3..................................................................................................... 16 3.......... 11 3. 32 4...1 ArcWare 3..1 Product Specification RobotWare for BaseWare OS The document is for study only..1 ......................................5 GlueWare 3...............................................1 ..................................................................................................................................................................................................................................................cadfamily............. 33 4.............................................................................. 45 5..............1.........................................Product Specification RobotWare CONTENTS Page 1 Introduction ...................com 3.................1 ...........................................................................1 The Rapid Language and Environment .........................3 Multitasking 3............................................................................................................................................................. 46 6 Index ..........1 .................... 47 www.....................................10 I/O Plus 3......9 Conveyor Tracking 3............ 40 4.............................1 (LidCode). please inform us.Product Specification RobotWare www.cadfamily.we will delete .com EMail:[email protected] The document is for study only.com 2 Product Specification RobotWare for BaseWare OS 3.if tort to your rights. perform advanced motion tasks etc.if tort to your rights. It is an inherent part of the robot but can be provided separately for upgrading purposes. gluing and painting.1 Product Specification RobotWare for BaseWare OS The document is for study only. These products also run on top of BaseWare OS.com EMail:[email protected] products are options that run on top of BaseWare OS of the robot. ABB Flexible Automation has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations.cadfamily.please inform us.ProcessWare products are designed for specific process applications like welding.Introduction 1 Introduction RobotWare is a family of software products from ABB Flexible Automation designed to make you more productive and lower your cost of owning and operating a robot.com 3. They represent functionality for robot users that need additional functionality. communicate with a PC. www. Within the RobotWare family there are five classes of products: BaseWare OS . They are primarily designed to improve the process result and to simplify installation and programming of applications.we will delete 3 . BaseWare OS provides all the necessary features for fundamental robot programming and operation. for example run multitasking. transfer information from file to robot. BaseWare Options .This is the operating system of the robot and constitutes the kernel of the RobotWare family. ProcessWare . Introduction www.please inform us.cadfamily.com 4 Product Specification RobotWare for BaseWare OS 3.com EMail:[email protected] The document is for study only.we will delete .if tort to your rights. . routines and I/O. only memory limited). It contains the following concepts: . including structured and array data types.if tort to your rights.Unlimited language (no max.Extensive program flow control. number of variables etc. .User defined names (shop floor language) on variables. user defined pick lists).com EMail:[email protected] based man machine interface with built-in Rapid support (e.we will delete 5 . e.g mathematics and robot specific. Safety.g.. . . www.Error handling (for exception handling in general.com 3. 2. .User defined instructions (appear as an inherent part of the system).1 Product Specification RobotWare for BaseWare OS The document is for study only.Hierarchical and modular program structure to support structured programming and reuse. . see references in Robot Documentation.cadfamily. the I/O System. see Exception handling).Routines can be Functions or Procedures. Motion Control. . Exception handling. . flexibility and powerfulness.Many powerful built-in functions. . . .please inform us. The properties of BaseWare OS can be split up in five main areas: The Rapid Language and Environment.Backward handler (user definition of how a procedure should behave when stepping backwards). .Rapid Language and Environment 2 BaseWare OS Only a very superficial overview of BaseWare OS is given here.Local or global data and routines.Data typing. For details.1 The Rapid Language and Environment The Rapid language is a well balanced combination of simplicity.Interrupt handling.Arithmetic and logical expressions. . please inform us. user defined messages.Restart on Path.1 The document is for study only. . .Exception handling 2. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time.Error Handlers (automatic recovery often possible without stopping production). .com EMail:[email protected] logging.com 6 Product Specification RobotWare for BaseWare OS 3. .2 Exception handling Many advanced features are available to make fast error recovery possible.we will delete .if tort to your rights. .Error messages: plain text with remedy suggestions.Service routines. www. Examples: .Power failure restart.cadfamily. .Diagnostic tests. 1 Product Specification RobotWare for BaseWare OS The document is for study only. External axes Very flexible possibilities to configure external axes. For big. Coordinate Systems A very powerful concept of multiple coordinate systems that facilitates jogging.com 3.3 Motion Control TrueMoveTM Very accurate path and speed. flexible objects it is possible to optimise the servo tuning to minimise load oscillation. the robot always and automatically optimises its performance for the shortest possible cycle time. i. sensor based applications.e.g.com EMail:cadserv21@hotmail. Note that also joint coordinate movements (MoveJ) are recalculated when a coordinate system is adjusted.Motion Control 2. off-line programming. No need for manual tuning! This is achieved without compromising the path accuracy. program adjustment. Includes for instance high performance coordination with robot movement and shared drive unit for several axes.we will delete 7 . external axes co-ordination etc. A further monitoring function.if tort to your rights.please inform us. copying between robots. based on advanced dynamic modelling. points where two axes coincide. www. Speed independent path. possibility to have separate zone sizes for Tool Centre Point (TCP) path and for tool reorientation). Flexible and intuitive way to specify corner zones (e.cadfamily. Singularity handling The robot can pass through singular points in a controlled way. is optional (see option “Load Identification and Collision Detection”). Big Inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. Full support for TCP attached to the robot or fixed in the cell (“Stationary TCP”). Motion Supervision The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not OK. QuickMoveTM By use of the dynamic model. Collision Detection. please inform us.cadfamily.Motion Control Soft Servo Any axis (also external) can be switched to soft servo mode. www.we will delete .com 8 Product Specification RobotWare for BaseWare OS 3.com EMail:[email protected] tort to your rights. which means that it will adopt a spring-like behaviour.1 The document is for study only. cadfamily. programmer.com 3. Motion Supervision See Motion Control. www.we will delete 9 . service & programmer). It is possible to define the commands available at the different levels. This limitation also works in joint system motion.com EMail:cadserv21@hotmail. Limited modpos It is possible to limit the allowed distance/rotation when modifying positions. the TCP and one user defined point (attached to the upper arm) to 250 mm/s (can be set lower).1 Product Specification RobotWare for BaseWare OS The document is for study only. service.if tort to your rights.4 Safety Many safety concepts reside in hardware and are not within the scope of this document. Authorisation It is possible to limit the access to certain commands by assigning different passwords to four different user levels (operator.Safety 2. the controller limits all parts of the robot body. However. some important software contributions will be mentioned: Reduced Speed In the reduced speed mode.please inform us. TCP-proportional analog signal. .Flexible cross connections.Program controlled enabling/disabling of I/O units.cadfamily.Up to 512 signals available (one signal = single DI or DO. .I/O System 2. . AI or AO). . what action to take when a unit is “lost”). www.Selectable “trust level” (i.please inform us.com EMail:cadserv21@hotmail. . . .Accurate coordination with motion. .Grouping of signals to form integer values. . .com 10 Product Specification RobotWare for BaseWare OS 3.5 I/O System Elementary I/O Robust and fast distributed system built on CAN/DeviceNet with the following features: .Polarity definition.Named signals and actions with mapping to physical signal (“gripper close” instead of “set output 1”). .if tort to your rights. Memory I/O RAM disk and floppy disk.Simulated I/O (for forming cross connections or logical conditions without need the for physical hardware).Programmable delays. . group of DI or DO. .Scaling of analog signals.Filtering.we will delete .Pulsing.e.Sophisticated error handling. Serial I/O XON/XOFF or SLIP.1 The document is for study only. . Examples of applications: . e.Information transfer via serial channels or files.Automatic setting of output when the robot is in a user-defined area. . The transfer is controlled entirely from the robot’s work program.1 Includes functions making the following possible: .1 Advanced Functions 3.Executing a routine at a specific position. e.Advanced Functions 3. .if tort to your rights.Setting an output at a specific position. during automatic error handling. numeric values or binary information can be transferred between the robot and other peripheral equipment.Reading part numbers from a bar code reader with a serial interface.Defining forbidden areas within the robot´s working space. use the option RAP Communication or FactoryWare Interface.1 3 BaseWare Options 3.Cross connections with logical conditions.1 Product Specification RobotWare for BaseWare OS The document is for study only.com EMail:cadserv21@hotmail. a PC.Robot motion in an error handler or trap routine. . . .Transferring data between the robot and a PC.com 3. When it is required to control the transfer from a PC.cadfamily.g.we will delete 11 .g. or another robot. . Information is transferred via an RS232 or RS485 serial channel.please inform us.Printout of production statistics on a printer connected to the robot. . www. bar code reader. Transferring information via serial channels Data in the form of character strings. . 1 Data transfer via files Data in the form of character strings. an output is set that starts the press. stored on a diskette. The output will then change at the same place every time. This time must be within the deceleration time when approaching that position. see GlueWare.please inform us. the output is set at the corresponding time before the robot reaches the specified position. irrespective of the robot’s speed. it may be necessary to check a number of logical conditions before setting the output that starts the press. By specifying this time delay (max. Examples of applications: .Handling press work.Advanced Functions 3. This file may have been created in a PC. analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. Fixed position procedure call A procedure call can be carried out when the robot passes the middle of a corner zone. Fixed position output The value of an output (digital. Example of application: .In the press example above. and read by the robot at a later time. www. The position will remain the same. Just as the robot leaves the press. A procedure which takes care of the complete press start operation is called at a position just outside the press. irrespective of the robot’s speed. When using this function.Storing production statistics on a diskette or ramdisk. The distance can also be specified as a certain time before the programmed position. For gluing and sealing. 500 ms). . .com 12 Product Specification RobotWare for BaseWare OS 3.com EMail:[email protected] and finishing process equipment. Consideration can also be given to time delays in the process equipment. This information can then be read and processed by an ordinary PC. the start will always occur at the same position irrespective of the speed.cadfamily. to provide a safe signalling system between the robot and the press. numerical values or binary information can be written to or read from files on a diskette or other type of mass storage/memory.we will delete . Examples of applications: .1 The document is for study only.if tort to your rights.The robot’s production is controlled by a file. which will reduce cycle times. com 3.com EMail:cadserv21@hotmail. both during program execution and when the robot is jogged into this area. the robot cannot run into the walls of the box. Examples of applications: . it sets an output and after that enters only when the corresponding output from the other robot is reset.cadfamily. i. .1 Product Specification RobotWare for BaseWare OS The document is for study only. By defining the outside of the box as a forbidden area. the PLC will check that the robot is inside the home volume. the corresponding output is set. This ensures that the robot cannot be moved into this volume. .A robot is working inside a box.The volume is defining where peripheral equipment is located within the working space of the robot. www. which are defined in the world coordinate system.Advanced Functions 3.1 World Zones A spherical. can be automatically activated at start-up or activated/deactivated from within the program. cylindrical or cubical volume can be defined within the working space.e. When the robot is started from a PLC.please inform us. . When one of the robots enters the common working space.if tort to your rights.A volume is defining the home position of the robot. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”. The areas.we will delete 13 .Handshaking between two robots both working in the same working space. Cleaning the welding gun when a welding fault occurs.please inform us.com 14 Product Specification RobotWare for BaseWare OS 3.we will delete .cadfamily. (This requires options ArcWare or ArcWare Plus.Via an input. This is all automatic.) . but only when output 5=1 and input 3=0.if tort to your rights. When program execution is later restarted (manually or automatically) the robot resumes the interrupted movement. there is normally a jump to the program’s error handler. for example. without any need to call the operator. at the position where the welding fault occurred. with the correct parameters.1 The document is for study only. the robot can be ordered to interrupt program execution and go to a service position. Functionality similar to that of a PLC can be obtained in this way. The robot stores information about the original movement path which allows it to be resumed later. Examples of applications: . The welding movement in progress can be stored and the robot is ordered to the cleaning position so that the nozzle can be cleaned.A register is to be incremented when input 5 is set. .com EMail:[email protected] Functions 3. When a welding fault occurs. www. Cross-connections with logical conditions Logical conditions for digital input and output signals can be defined in the robot’s system parameters using AND.Input 3 = Output 7 OR NOT Output 8. Example: .1 Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one.Program execution to be interrupted when both inputs 3 and 4 become high. The welding process can then be restarted. .Output 1 = Input 2 AND Output 5. OR and NOT. Examples of applications: . 1 RAPID instructions and functions included in this option Open Close Write WriteBin WriteStrBin ReadNum ReadStr ReadBin Rewind WZBoxDef WZCylDef WZLimSup WZSphDef WZDOSet WZDisable WZEnable WZFree StorePath RestoPath TriggC TriggL TriggJ TriggIO TriggEquip TriggInt MoveCSync MoveLSync MoveJSync Opens a file or serial channel Closes a file or serial channel Writes to a character-based file or serial channel Writes to a binary file or serial channel Writes a string to a binary serial channel Reads a number from a file or serial channel Reads a string from a file or serial channel Reads from a binary file or serial channel Rewind file position Define a box shaped world zone Define a cylinder shaped world zone Activate world zone limit supervision Define a sphere shaped world zone Activate world zone to set digital output Deactivate world zone supervision Activate world zone supervision Erase world zone supervision Stores the path when an interrupt or error occurs Restores the path after an interrupt/error Position fix output/interrupt during circular movement Position fix output/interrupt during linear movement Position fix output/interrupt during joint movement Definition of trigger conditions for one output Definition of trigger conditions for process equipment with time delay Definition of trigger conditions for an interrupt Position fix procedure call during circular movement Position fix procedure call during linear movement Position fix procedure call during join movement www.com 3.cadfamily.com EMail:[email protected] Product Specification RobotWare for BaseWare OS The document is for study only.Advanced Functions 3.please inform us.if tort to your rights.we will delete 15 . www. . Note! There is a built-in general method for defining the geometry for a manipulator comprising two rotating axes (see User’s Guide. without having to physically rotate it back again. the work object is often fitted to a rotating external axis.2 Advanced Motion 3.Coordinated motion with external manipulators.Advanced Motion 3. e. Please contact your nearest ABB Flexible Automation Centre. Examples of applications: . If this axis is rotated more than one turn during welding.1 Contains functions that offer the following possibilities: . It can now be reset using this function. Note that simultaneous coordination with several single axis manipulators.Resetting the work area for an axis.g. . Obviously this will reduce cycle times.please inform us.we will delete . comprising up to six linear and/or rotating axes. For other types of manipulators/robot carriers. the cycle time can be reduced because it is not necessary to rotate the axis back between welding cycles.When polishing.com EMail:cadserv21@hotmail. a special configuration file is needed. Assume that the axis has rotated 3 turns.if tort to your rights.When arc welding. .cadfamily.1 3. Calibration).1 The document is for study only. does not require Advanced Motion.Independent movements. Resetting the work area for an axis The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements.Contour tracking.com 16 Product Specification RobotWare for BaseWare OS 3. Coordinated motion with multi-axis manipulators Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires the Advanced Motion option. for example. a large work area is sometimes needed on the robot axis 4 or axis 6 in order to be able to carry out final polishing without stopping. . track motion and workpiece manipulator. for example.if tort to your rights. Independent movements A linear or rotating axis can be run independently of the other axes in the robot system. a friction effect. The input can be defined via an analog input. An interrupt or multitasking is therefore required to activate the correction during motion. no significant effects can be expected by applying Friction Compensation. www.1 Product Specification RobotWare for BaseWare OS The document is for study only.A robot is working with two different stations (external axes). Advanced Motion offers a possibility of compensating for these frictional effects.com EMail:[email protected] Contour tracking Path corrections can be made in the path coordinate system.cadfamily. can be noted. When this is finished the work area is reset for the external axis in order to shorten the cycle time.we will delete 17 . station 1 is moved to a position where it is easy to change the work object and at the same time the robot welds the work object at station 2. Multitasking or interrupts are used to read this information at specific intervals. Note that even with careful tuning. First.5 mm “bumps”. there is no guarantee that “perfect” paths can always be generated. These corrections will take effect immediately. The independent movement can be programmed as an absolute or relative position. typically in the form of approximately 0. Typically a 0. the path can then be adjusted. Based on the input value. For the IRB 6400 family of robots.com 3. a work object located at station 1 is welded.Advanced Motion 3.A sensor is used to define the robot input for path correction during motion. Friction Compensation During low speed (10-100 mm/s) cutting of fine profiles.1 mm. In the mean time. however. the robot sprays plasma. This. on the work object. requires careful tuning of the friction level (see User’s Guide for tuning procedure).The work object is located on an external axis that rotates continuously at a constant speed.please inform us. which simplifies programming and reduces the cycle time. A continuous movement with a specific speed can also be programmed. in particular small circles.5 mm “bump” can be reduced to about 0. Example of application: . When this operation is completed. Examples of applications: . also during movement between two positions. a serial channel or similar. The path corrections must be entered from within the program. . Station 1 is moved independently of the robot’s movement. we will delete . There are two alternatives: . For further information about DMC and FBU. This can be of interest.com EMail:[email protected] V) or a field bus. without taking into consideration the number of turns the axis had rotated earlier Running an axis continuously in independent mode Checking whether or not an independent axis has reached the programmed position Checking whether or not an independent axis has reached the programmed speed Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators www.if tort to your rights.Advanced Motion 3. the possibility to connect off-the-shelf standard drive systems for controlling external axes is available.1 External Drive System With Advanced Motion.com 18 Product Specification RobotWare for BaseWare OS 3. RAPID instructions and functions included in this option IndReset IndAMove IndDMove IndRMove IndCMove IndInpos IndSpeed CorrCon CorrWrite CorrRead CorrDiscon CorrClear Resetting the work area for an axis Running an axis independently to an absolute position Running an axis independently for a specified distance Running an axis independently to a position within one revolution.The Atlas Copco Controls´ FBU (Field Bus Unit) that can handle up to three external drive units per FBU unit. The drive board can thus be of virtually any make and type. . NOTE! The DMC/FBU must be equipped with Atlas Copco Controls option C.1 The document is for study only.cadfamily. for example. These can be connected to analog outputs (+/.The Atlas Copco Controls´ stand alone servo amplifier DMC.please inform us. when the power of the available S4C drives does not match the requirements. please contact Atlas Copco Controls. .e.we will delete 19 .Because monitoring is implemented via interrupts (instead of checking conditions at regular intervals). . . the operator can specify input data for the next work cycle without having to stop the robot. each process in addition to the main process will reduce the total memory.Multitasking 3. i.com EMail:[email protected] are programmed using standard RAPID instructions. processor time is required only when something actually happens.1.These additional tasks start automatically at power on and will continue until the robot is powered off.When the priorities for the various processes are correctly set. welding. for example.cadfamily. .They can be programmed to carry out various activities in manual or automatic mode.3 Multitasking 3. Note that the response time of Multitasking does not match that of a PLC.1 3. thus taking over the job traditionally allocated to a PLC.The robot is controlling a piece of external equipment in parallel with the normal program execution. The available program memory can be divided up arbitrarily between the processes. However. the normal program execution of the robot will not be affected. except for motion instructions.Priorities can be set between the processes. .1 Product Specification RobotWare for BaseWare OS The document is for study only.1 Up to 10 programs (tasks) can be executed in parallel with the normal robot program. and depending on whether or not the main process is running. Multitasking is primary intended for less demanding tasks.All input and output signals are accessible for each process. By putting this operator dialogue into a background task.com 3. .please inform us.An operator dialogue is required at the same time as the robot is doing. . Performance When the various processes are programmed in the correct way. Examples of applications: .The robot is continuously monitoring certain signals even when the robot program has stopped. no performance problems will normally occur: . . www. even when the main process has been stopped and in manual mode. see section 5.if tort to your rights.Communication between tasks is carried out via I/O or global data. . 1 includes the Robot Application Protocol (RAP). when developing such an application.0 or later versions (see FactoryWare).Transfer system parameters to/from the robot . However.Transfer files to/from the robot .Read the robot status .Start and stop program execution . The Factory Ware Interface 3.Read and write output signals . This option will also work with RobView 3. or only password for only run-time).cadfamily.if tort to your rights.1/1 or DDE Server 2.Read error messages . i. Older versions of RobComm will require RAP Communication in the robot and license protection in the PC (hardware lock and password for design and run-time.1 This option enables the robot system to communicate with a PC using RobComm 3. The Robot Application Protocol is used for computer communication.Read input signals . as illustrated by the figure below. a hardware lock and password are needed in the PC (design time license). The following functions are supported: .please inform us.com EMail:cadserv21@hotmail. Older versions work only with RAP Communication.e. the PC does not require any license protection when executing a RobComm based application.we will delete .com 20 Product Specification RobotWare for BaseWare OS 3.4 FactoryWare Interface 3.1 The document is for study only. based on MMS functionality. RAP RPC (Remote Procedure Call) TCP/IP Standard protocols SLIP RS232/RS422 Ethernet www.1 serves as a run-time license for RobComm. In all cases RobView and DDE Server will require the hardware lock and password.FactoryWare Interface 3. The FactoryWare Interface 3.Transfer programs to/from the robot .Read logs RAP communication is available both for serial links and network.Read and write data .Change robot mode .1 3.3/1 (or later versions). When many different programs are used in the robot.FactoryWare Interface 3. Program execution is started and stopped from the computer.cadfamily.if tort to your rights. .we will delete 21 . RAPID instruction included in this option SCWrite Sends a message to the computer (using RAP) www. When execution of this program has finished. .com 3.Production is controlled from a superior computer. etc.1 Product Specification RobotWare for BaseWare OS The document is for study only.please inform us. the computer helps in keeping track of them and by doing back-ups.com EMail:[email protected] Examples of applications: .Programs can be transferred to the robot’s ramdisk at the same time as the robot executes its normal program. In this way a large number of programs can be handled and the robot’s memory does not have to be so big. Information about the robot status is displayed by the computer.Transferring programs and parameters between the robot and a PC. the new program can be read very quickly from the ramdisk and program execution can continue. in this case a license protection requirement in the PC is added.1 The document is for study only. For RobView and DDE Server.1 3. are used. It includes the same functionality described for the option Factory Ware Interface 3.please inform us. It also works for the FactoryWare products.5 RAP Communication 3.com 22 Product Specification RobotWare for BaseWare OS 3.RAP Communication 3. or DDE Server.if tort to your rights.cadfamily. there is no difference from the FactoryWare Interface (except that the price is higher).1. RobView.1 This option is required for all communication with a superior computer.com EMail:cadserv21@hotmail. Note that both FactoryWare Interface and RAP Communication can be installed simultaneously.we will delete . www. For RobComm. where none of the FactoryWare products RobComm. www.Ethernet Services 3.com EMail:cadserv21@hotmail. the hard disk in a PC. A software update or a program backup can easily be executed from the PC.we will delete 23 .e.1 Product Specification RobotWare for BaseWare OS The document is for study only.g. This is done by a manual command from the teach pendant or an instruction in the program. e.1 Information in mass storage. The robot control program can also be booted via Ethernet instead of using diskettes.6 Ethernet Services 3. . The control program and the user programs for all the robots are stored on the PC.Several robots are connected to a PC via Ethernet. Examples of applications: .cadfamily. it can also be done by a command from the PC (without using the ramdisk as intermediate storage). can be read directly from the robot. i. This requires Ethernet hardware in the robot.com 3. a new program is to be loaded. If the option RAP Communication or FactoryWare Interface is used.1 3.if tort to your rights.please inform us. When a new part is to be produced. the program can be read directly from the hard disk of the PC.All programs for the robot are stored in the PC. com EMail:cadserv21@hotmail. www. If applicable. This may be necessary when strong process forces are acting on the robot. and three inertia components). Performing identification.Load Identification and Collision Detection 3.we will delete . Operating a robot with inaccurate load parameters can have a detrimental influence on cycle time and path accuracy.if tort to your rights. Tuning is normally not required. 5 and 6 during approximately three minutes. the robot can carry out accurate identification of the complete load data (mass. RAPID instructions included in this option MotionSup ParldRobValid ParldPosValid LoadId Changing the sensitivity of the collision detection or activating/deactivating the function.7 Load Identification and Collision Detection 3. With LidCode. The identification procedure consists of limited predefined movements of axes 3. but the sensitivity can be changed from Rapid or manually (the supervision can even be switched off completely). Collision Detection Abnormal torque levels on any robot axis (not external axes) are detected and will cause the robot to stop quickly and thereafter back off to relieve forces between the robot and environment. finally.cadfamily. Checking that the current position is OK for identification. LidCode contains two very useful features: Load Identification To manually calculate or measure the load parameters accurately can be very difficult and time consuming. The sensitivity (with default tuning) is comparable to the mechanical alternative (mechanical clutch) and in most cases much better. tool load and payload are handled separately. Two system outputs reflect the activation and the trig status of the function. the adjustable tuning.1 The document is for study only. Checking that identification is available for a specific robot type.com 24 Product Specification RobotWare for BaseWare OS 3. LidCode has the advantages of no added stick-out and weight. no need for connection to the e-stop circuit. In addition.1 (LidCode) 3.1 (LidCode) This option is only available for the IRB 6400 family of robots.please inform us. centre of gravity. the automatic backing off after collision and. The starting point of the identification motion pattern can be chosen by the user so that collisions are avoided. no wear. The accuracy achieved is normally better than 5%. 1 This option adds a user window to display user defined screens with advanced display functions.cadfamily.com EMail:[email protected] 3. • 1 to 4 pop-up menus containing from 1 to 10 choices.8 ScreenViewer 3.1 3. . hexadecimal.Their type (display.ScreenViewer 3. decimal.Their display format (integer.we will delete 25 . input). • 1 to 30 display and input fields defined by: . . regardless of the execution state of the RAPID programs.1 Product Specification RobotWare for BaseWare OS The document is for study only. Example of a user defined screen. These characters can be ASCII and/or horizontal or vertical strokes (for underlining. binary. The user window can be displayed at any time. separating or framing).Their position and size. • 1 to 5 function keys.A possible boundary with minimum and maximum limits.please inform us. text). (Copy) File View Heat stepper: ### interpolated: ## | | Tolerance: ###% | Force: ###daN | Forge: ###daN | | Fire chck: ### | | Err allow: ###% | Numb err: ### PHASES SQUEEZE PREHEAT COOLING ## HEAT COLD LASTCOLD POSTHEAT HOLD Next | | | | | | | | | XT ## ## ## ## ## ## ## ## Valid www. User defined screens The user defined screens are composed of: • A fixed background with a size of 12 lines of 40 characters each. .if tort to your rights. The ### represent the fields. SpotTim Program number: ### | | | | | | | | | | CURENT (A) START | END | #### | | #### #### | | | #### | #### | Prev. . www. field modified.if tort to your rights. or when a new field is selected (to execute some specific action).Reading/writing fields contents. /. Capacities The user screens can be grouped in a screen package file under a specific name.we will delete . .Reading/writing RAPID or I/O data. A screen event can occur .Displaying a different screen. A list of user screen commands can be associated with any of these events. function key pressed. -. then when the event occurs.com 26 Product Specification RobotWare for BaseWare OS 3. or change the screen). *. OR.When a new screen is displayed (to initialize the screen contents). NOT. XOR) operations on the data read. >) and carrying out a command or not.1 Advanced Display functions The user defined screens run independently of the RAPID programs. Up to 8 packages can be loaded at the same time. . .When a new value is entered in a field. The commands that can be executed on screen events are . . div) or logical (AND. 50 kbytes) is reserved for loading these screen packages.1 The document is for study only.. A certain amount of memory (approx. ..cadfamily.com EMail:cadserv21@hotmail. .Arithmetical (+. menu choice selected.After a chosen interval (to refresh a screen).ScreenViewer 3. the command list will be executed. depending on the comparison result.Comparing data read (=.).please inform us.When a menu choice or a function key is selected (to execute a specific action.The screen package to be displayed is selected using the far right hand menu “View” (which shows a list of the screen packages installed). Some events occur on a screen (new screen displayed. <. . . even when the conveyor speed is changing slowly.com 3. .1 Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor.1 Product Specification RobotWare for BaseWare OS The document is for study only. . the programmed TCP speed relative to the work object will be maintained. When the robot is stationary relative to the conveyor.It is possible to have two conveyors connected simultaneously and to switch between tracking the one or the other.1 3. i. the TCP will remain within 0.7 mm of the intended position.we will delete 27 . While tracking the conveyor. RAPID instructions included in this option WaitWObj DropWObj Connects to a work object in the start window Disconnects from the current object www. it is not necessary to stop in a fine point.please inform us. Note that hardware components for measuring the conveyor position are also necessary for this function. .It is possible to define a start window in which an object must be before tracking can start.cadfamily. the TCP will stay within +/-2 mm of the path as seen with no conveyor motion. . .If the robot is mounted on a parallel track motion.9 Conveyor Tracking 3.A maximum tracking distance may be specified.A conveyor can be defined as either linear or circular.if tort to your rights. These values are valid as long as the robot is within its dynamic limits with the added conveyor motion and they require accurate conveyor calibration.com EMail:cadserv21@hotmail. then the system can be configured such that the track will follow the conveyor and maintain the relative position to the conveyor. Performance At 150 mm/s constant conveyor speed. Please refer to the Product Specification for your robot.Tracking of a conveyor can be activated “on the fly”.Up to 254 objects can reside in an object queue which can be manipulated by RAPID instructions.e. . Conveyor Tracking provides the following features: .Conveyor Tracking 3. com EMail:cadserv21@hotmail. and is not intended for general use. The user must provide the appropriate configuration data. please contact the supplier.I/O Plus 3.Wago modules with DeviceNet fieldbus coupler. . the I/O Plus option also opens up the possibility to use other digital I/O units that conform with the DeviceNet specification.please inform us. Configuration data for the units is included. The communication between these units and S4C has been verified (this does not. ABB Robotics Products AB does not assume any responsibility for the functionality or quality of such units.if tort to your rights.1 The document is for study only.10 I/O Plus 3.Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1 (8 digital input signals and 8 digital output signals). . however. www.we will delete . For more information on any of these untis. item 750-306 revision 3. In I/O Plus there is also support for a so-called “Welder”.com 28 Product Specification RobotWare for BaseWare OS 3. guarantee the internal functionality and quality of the units).Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2 (16 digital input signals). In addition to the above units.1 3. This is a project specific spot welding timer. The following units are supported: .cadfamily.1 I/O Plus enables the S4C to use non-ABB I/O units. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. Automatic weld retry A function that can be configured to order one or more automatic weld retries after a process fault. www. wire feed rate.1 Product Specification RobotWare for BaseWare OS The document is for study only. These can be used to fill the weld properly and in the best possible way.1 ArcWare 3.com 3.ArcWare 3.please inform us. Normally communication with the welding controller uses parallel signals but a serial interface is also available. I/O signals. Testing the program When testing a program.we will delete 29 . Weaving The robot can implement a number of different weaving patterns up to 10 Hz depending on robot type. Adaptation to different equipment The robot can handle different types of weld controllers and other welding equipment. Advanced process control Voltage.cadfamily. which make the robot well suited for arc welding.1 ArcWare comprises a large number of dedicated arc welding functions. Weaving movement can also be ordered at the start of the weld in order to facilitate the initial striking of the arc. and other process data can be controlled individually for each weld or part of a weld. ArcWare functions A few examples of some useful functions are given below.if tort to your rights. This provides a way of testing the robot program without having the welding equipment connected. timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. The process data can be changed at the start and finish of a welding process in such a way that the best process result is achieved.com EMail:cadserv21@hotmail. weaving or weld guiding can all be blocked. welding.1 4 ProcessWare 4. 1 Wire burnback and rollback These are functions used to prevent the welding wire sticking to the work object. voltage and weaving can all be adjusted whilst welding is in progress. starts weld motion Weld voltage supervision Weld current supervision Water supply supervision Gas supply supervision Wire supply supervision Manual command for wire feed Blocks the welding process Blocks the weaving process Stops/inhibits execution of arc welding instructions Wirestick supervision Program execution without supervision Torch collision supervision Description Weld voltage Velocity of wire feed Weld current Voltage synergic line amplification Current synergic line amplification Digital inputs Arc OK Voltage OK Current OK Water OK Gas OK Wire feed OK Manual wire feed Weld inhibit Weave inhibit Stop process Wirestick error Supervision inhibit Torch collision Analog outputs Voltage Wire feed Current Voltage adjustment Current adjustment www.we will delete .com EMail:cadserv21@hotmail. Interface signals The following process signals are. The robot can also support dedicated signals for workpiece manipulators and sensors.ArcWare 3. or Serial CAN/Devicenet communication Description Arc established.com 30 Product Specification RobotWare for BaseWare OS 3. Weld Guiding Weld guiding can be implemented using a number of different types of sensors. This can be done in both manual and automatic mode.please inform us. or 3-bit pulse port for selection of program number.1 The document is for study only. Digital outputs Power on/off Gas on/off Wire feed on/off Wire feed direction Weld error Error information Weld program number Description Turns weld on or off Turns gas on or off Turns wire feed on or off Feeds wire forward/backward Weld error Digital outputs for error identification Parallel port for selection of program number.if tort to your rights. Please contact your nearest ABB Flexible Automation Centre for more information. This makes trimming of the process much easier because the result can be seen immediately on the current weld. handled automatically by ArcWare.cadfamily. Fine adjustment during program execution The welding speed. if installed. wire feed rate. please inform us.ArcWare 3.cadfamily.we will delete 31 .) Voltage Current Description (cont.1 Product Specification RobotWare for BaseWare OS The document is for study only.) Weld voltage measurement for monitoring and supervision Weld current measurement for monitoring and supervision RAPID instructions included in this option ArcL ArcC Arc welding with linear movement Arc welding with circular movement www.1 Analog inputs (cont.com 3.com EMail:[email protected] tort to your rights. Contour tracking.cadfamily. The path corrections must be entered from within the program.ArcWare Plus 3.com 32 Product Specification RobotWare for BaseWare OS 3.Arc data monitoring. The function predicts weld errors. see previous chapter. The input can be defined via an analog input. .please inform us. These values can be used to adapt the process parameters to the current shape. Multitasking or interrupts are used to read this information at specific intervals. .ArcWare.1 ArcWare Plus contains the following functionality: .1 4. a serial channel or similar. Adaptive process control for LaserTrak and Serial Weld Guide systems.we will delete . Example of application: A sensor is used to define the robot input for path correction during motion. Arc data monitoring with adapted RAPID instructions for process supervision. RAPID instructions and functions included in this option ArcKill ArcRefresh CorrCon CorrWrite CorrRead CorrDiscon CorrClear SpcCon SpcWrite SpcDump SpcRead SpcDiscon Aborts the process and is intended to be used in error handlers Updates the weld references to new values Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators Activates statistical process supervision Provides the controller with values for statistical process supervision Dumps statistical process supervision data to a file or on a serial channel Reads statistical process supervision information Deactivates statistical process supervision www. also during movement between two positions.com EMail:cadserv21@hotmail. Path corrections can be made in the path coordinate system.1 The document is for study only. .Adaptive process control. These corrections will take effect immediately. An interrupt or multitasking is therefore required to activate the correction during motion. Based on the input value. the path can then be adjusted.if tort to your rights. The tool provides the robot system with changes in the shape of the seam.2 ArcWare Plus 3. the gun can be closed correctly regardless of the speed of the robot. The cycle time is optimised when the gun is just about to close at the instant when the robot reaches the programmed point. By defining a time of closure.com EMail:cadserv21@hotmail. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction.please inform us.SpotWare 3. Normally communication with the weld timer uses parallel signals but a serial interface is also available for some types of weld timers. This gives a constant time between gun closure and weld start. i. www. I/O signals. without waiting for the robot to reach its final position. Adaptation to different welding guns Gun control (opening and closing) can be programmed freely to suit most types of guns. Adaptation to different weld timers The robot can handle different types of weld timers.1 SpotWare comprises a large number of dedicated spot welding functions which make the robot well suited for spot welding. together with the fact that movement can commence immediately after a spot weld is completed.e. Continuous supervision of the welding equipment If the option Multitasking is added. supervision can be implemented irrespective of the spotweld instruction.cadfamily. Closing the gun It is possible to start closing the spot welding gun before reaching the programmed point. timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. also contributes to making cycle times shorter.1 4. SpotWare functions A few examples of some useful functions are given below.com 3. Constant squeeze time Welding can be started directly as the gun closes.1 Product Specification RobotWare for BaseWare OS The document is for study only.3 SpotWare 3. which results in fast acceleration and a quick approach to the spot weld.if tort to your rights. For example. irrespective of the signal interface. it is possible to monitor peripheral equipment even when program execution has been stopped. Customised Move enable The movement after a completed spot weld can be configured to start either on a user defined input signal or a delay time after weld ready.we will delete 33 . The robot’s self-optimising motion control. Cycle times can be shortened by means of closing the spot welding gun in advance. we will delete . handled automatically by SpotWare. both forwards and backwards. together with an inverted gun movement.please inform us.SpotWare 3. This makes the program easier to test. with gun control and process supervision. When the appropriate routine has been performed.com 34 Product Specification RobotWare for BaseWare OS 3. small and large strokes and gun pressure control. if installed. Testing the program The program can be run one instruction at a time. Gun control The system supports double guns. The program can also be test run without connecting a weld timer or spot welding gun. Process error routines In the event of a process error.com EMail:cadserv21@hotmail. installation-specific routines. Several guns can be controlled in the same program. Manual welding independent of positioning A spot weld can be ordered manually at the current robot position. can be ordered manually. This is implemented in a similar way as for program execution.1 Immediate move after Move enable The robot moves immediately when enable is given. the weld cycle continues from where it was interrupted. Rewelds A function that can be configured to order one or more automatic rewelds or. such as go-to-service position. This is achieved by preparing the next action while waiting for the current weld to be completed.e.1 The document is for study only. only motion instructions. Interface signals The following process signals are. When it is run backwards. when the program is restarted after an error. It is also possible to order a separate gun control with full supervision.cadfamily. a manual reweld. Digital outputs start 1 start 2 close tip 1 close tip 2 work select program parity reset fault process error current enable p2 request p3 request p4 request weld power water start Description start signal to the weld timer (tip 1) start signal to the weld timer (tip 2) close gun (tip 1) close gun (tip 2) select work or retract stroke of the gun weld program parity bit reset the weld timer operator request is set when an error occurs weld inhibit to the weld timer set pressure 2 set pressure 3 set pressure 4 activate the weld power unit contactor activate water cooling www. i. are executed.if tort to your rights. is finished weld.1 Product Specification RobotWare for BaseWare OS The document is for study only. started with start 2.SpotWare 3. Routine preweld supervision postweld supervision init supervision motor on action motor off action process OK action process error action current enable action current disable action close gun open gun set pressure service close gun service open gun service weld fault Description supervision to be done before welding supervision to be done after welding supervision to be done for a warm start action to be taken for Motors On action to be taken for Motors Off action to be taken for welding sensor OK action to be taken for a process error action to be taken for current enable action to be taken for current disable definition of gun closing definition of gun opening definition of gun pressure setting error handling when gun pressure is not achieved error handling at timeout for gun opening error handling at timeout for weld-ready signal close gun manually open gun manually run a complete spot weld skip the ongoing action send data for the manual actions process is executed block spot welding movement weld ready timeout Description weld program number used for several weld timers Description weld. started with start 1. initiate Digital inputs weld ready 1 weld ready 2 tip 1 open tip 2 open tip 1 retract tip 2 retract p1 OK p2 OK p3 OK p4 OK timer OK flow OK temp OK current OK User defined routines The following routines are predefined but can be adapted to suit the current installation.if tort to your rights.com 3. is finished the gun (tip 1) is open the gun (tip 2) is open the gun (tip 1) opened to retract stroke the gun (tip 2) opened to retract stroke pressure 1 is reached pressure 2 is reached pressure 3 is reached pressure 4 is reached the weld timer is ready to weld no problem with the water supply no over-temperature the weld current is within permissible tolerances The option Advanced functions is included. www.please inform us.we will delete 35 .com EMail:[email protected] manual close gun manual open gun manual run process manual skip process manual new data process run inhibit move weld error Digital output groups program no.cadfamily. 1 RAPID instructions included in this option SpotL Spot welding with linear movement www.we will delete .com 36 Product Specification RobotWare for BaseWare OS 3.com EMail:[email protected] inform us.1 The document is for study only.cadfamily.SpotWare 3.if tort to your rights. com EMail:[email protected] will delete 37 .if tort to your rights.1 In addition to the SpotWare functionality the robot can weld with up to four stationary welding guns simultaneously.1 4.SpotWare Plus 3.1 Product Specification RobotWare for BaseWare OS The document is for study only. RAPID instructions included in this option SpotML Multiple spot welding with linear movement.4 SpotWare Plus 3. www.com 3.please inform us.cadfamily. GlueWare 3. GlueWare functions A few examples of some useful functions are given below.please inform us. Adaptation to different gluing guns Both on/off guns and proportional guns can be handled.1 The document is for study only. Up to two analog outputs can be controlled for each gun.5 GlueWare 3.1 4.if tort to your rights. Two gluing guns One or two gluing guns can be controlled. thanks to a proactive signal. When the robot velocity is reduced. which makes the programming much simpler.1 GlueWare comprises a large number of dedicated gluing functions which make the robot well suited for gluing and sealing. also where there are no programmed positions. I/O signals and timing sequences can be easily configured to meet the requirements of a specific installation. Furthermore. www. Velocity independent glue string thickness The thickness of the glue string can be made independent on the robot’s velocity by controlling the gluing gun with a signal that reflects the robot’s velocity. It is a simple yet powerful program since both the positioning of the robot and the process control are handled in one and the same instruction. These positions will remain fixed even when the velocity is changed. start and stop) can be put into the programmed path. Flow change at a specific position Flow changes (incl. Program testing without glue Gluing can be temporarily blocked in order to be able to test the robot’s movements without any glue flow. time delays can be specified for the gluing guns in order to obtain the correct thickness of glue or sealing compound and application at the specified time.we will delete . The robot can compensate for a gun delay of up to 500 ms.com 38 Product Specification RobotWare for BaseWare OS 3. the flow of glue will be automatically reduced.com EMail:[email protected]. Global flow changes The glue flow can be changed for the whole program just by changing one value. Routine preglue actions postglue actions power on action restart action stop action emergency stop action Description activity to be carried out in the beginning of the glue string activity to be carried out at the end of the glue string activity to be carried out at power-on activity to be carried out at program start activity to be carried out at program stop activity to be carried out in the event of an emergency stop or other safeguarded space stop Description Glue flow reference gun 1 Glue flow reference gun 1 Glue flow reference gun 2 Glue flow reference gun 2 Description glue off/on gun1 glue off/on gun 2 the calculated value of an analog output signal is greater than its logical max.com EMail:[email protected] 3.we will delete 39 .1 Interface signals When installed.cadfamily.if tort to your rights. value error during gluing The option Advanced functions is included.1 Product Specification RobotWare for BaseWare OS The document is for study only. RAPID instructions included in this option GlueL GlueC Gluing with linear movement Gluing with circular movement www.GlueWare 3. Analog outputs gun1 flow1 gun1 flow 2 gun2 flow1 gun2 flow 2 Digital outputs gun 1 on/off gun 2 on/off overspeed error process error User defined routines The following routines are predefined but can be adapted to suit the current installation. the following process signals are handled automatically by GlueWare.please inform us. A maximum of ten events can be held within one PaintL instruction. etc.com EMail:[email protected] 4. due to trig plane events. The Rotation speed reference (for rotational applicators). The Atomising air reference. called a BrushTable. PaintWare is only avaliable with painting robots. or may go to dedicated I/O boards for closed loop gun control (IPS). Data types included in this option BrushData EventData Data for one brush: flow. A set of gun process parameters is called a Brush and it is possible to select different brushes during a linear paint instruction. the fluid and air flow through the spray gun is controlled to suit the part being coated and the thickness requirements. All phases of the paint process are controlled. Data for one event: trig-plane (x. The paint process is monitored continuously. PaintC.com 40 Product Specification RobotWare for BaseWare OS 3. The Brushes are set up as an array.cadfamily. PaintWare functionality When painting. The Electrostatic voltage reference. These process parameters are changed along the path to achieve optimum control of the paint equipment along an entire path.6 PaintWare 3. A brush can contain up to five parameters: Paint Atom_air Fan_air Voltage Rotation The Paint flow reference. It is powerful. such as start.please inform us. y or z). plane value and brush numberPaintL. The Fan air reference. atomising air. The five parameters may go directly to analog outputs controlling the spray gun in an open loop system. Event data is included in all linear paint instructions as optional arguments.1 The document is for study only. change.if tort to your rights. yet simple since both the robot positioning and the paint events are handled in one and the same instruction.we will delete . The changing of brushes along a path is done using events in the PaintL instruction. A specific BrushTable is selected with the instruction UseBrushTab. The necessary structures for paint process data are predefined and organised as BrushData and BrushTables. UseBrushTab. and stop painting.PaintWare 3. fan air.1 PaintWare comprises a large number of dedicated painting functions which make the robot well suited for painting and coating operations. It also describes which brush to use when the path crosses the plane. www. The event data describes how a trig plane is located in the active object coordinate system. www.we will delete 41 .1 Product Specification RobotWare for BaseWare OS The document is for study only.1 RAPID instructions included in this option PaintL PaintC UseBrushTab SetBrush Paint along a straight path w/paint events Paint along a circular path Used to activate (select) a brush-table.com 3.if tort to your rights.com EMail:cadserv21@hotmail. Select a brush from the activated brush-table.please inform us.PaintWare 3.cadfamily. with an individual coordinate system (work object).7 PalletWare General The PalletWare package is a set of Rapid modules and user screens. Each layer may be either an in-feeder layer. Each pallet cycle includes a number of layer cycles. where each pick-place cycle is the task to pick one or several parts and place them on the pallet. The tool to use may be a mechanical gripper or a tool with suction cups. to pick and place all products.if tort to your rights. The PalletWare package is intended to work with Rapid modules generated from PalletWizard. Within each pick-place cycle there may be several pick operations. Similarly. i.e. www. Several different tooldata may be defined and used depending on the product dimensions and number of products. Pallet cycles Up to five different pallet cycles may be run in parallel. possibly with separate grip zones for multiple picking and placing.g. where each layer cycle is the task to complete one layer with all the parts to be picked and placed in this layer.we will delete . or a stack layer. where the product.4. where the products. there may be several place operations in each pick-place cycle. e. Each layer cycle may further be broken down into a number of pick-place cycles. in-feeders and stacks for pallets. are picked from an in-feeder.1 The document is for study only. boxes. The palletizing robot is normally an IRB 6400 or IRB 640 but any robot type may be used. a PC tool for off-line programming of pallet cycles. if parts must be picked in many separate operations.com EMail:cadserv21@hotmail. where a pallet cycle is the task to run a complete palletizing job for a pallet. is searched and picked from a stack. All such stations and stacks are defined as regards position. For each such task a number of separate dynamic variables are used to describe and keep track of each on-going pallet operation. then one complete pick-place cycle is always finished before a new one is started in another pallet cycle. an empty pallet.g. These operations include a number of services which can be called from a main program to perform pick and place operations for one or up to five palletizing tasks in parallel.com 42 Product Specification RobotWare for BaseWare OS 3. If several pallet cycles are run in parallel. tier sheets or slip sheets. Pallet cell The pallet cell may include any number of pallet stations.please inform us. which perform basic operations related to a palletizing process.cadfamily. e. including the pallet itself. User routines A number of different user routines may be called at certain phases of the pallet cycle.g. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place on a feeder or pallet station. . Products may be delivered on one or several in-feeders and placed on one or several different pallets. The dimensions and speeds of the products may be changed in run time. These approach data may be changed in run time. connected to stacks. e. pick and place cycle.if tort to your rights. e. may be individually defined per product or station. connected to the different cycles. at the middle and at the end of the cycle. the robot will first move to an approach position and then to a prepick/place position. The picking and placing movements and the sequence to search different stacks for empty pallets or tier sheets may be customised if necessary. approach and retreat positions All movements are calculated in run time and relative to the different coordinate systems defined for each station.Station access routines.Pick stack routines. These horizontal and vertical distances for the approach positions.e. Between stations. thus affecting all pick and place positions. layer cycle.com EMail:cadserv21@hotmail. www.please inform us.1 Product Specification RobotWare for BaseWare OS The document is for study only. but different layers on a pallet may have different products.Products Any number of different products with different dimensions may be handled and placed in different patterns on the pallet. moving from an in-feeder to a pallet station.com 3. Each layer must have the same product only. The groups are: . the robot may be forced to move up to safety height and to retract before moving towards the new station.Cycle routines. These routines can be used for communication with external equipment. In addition. Each such cycle may have its own individual user routine at the beginning. . Such routines are called to search and pick a product on the stack. While moving to the pick or place position. for operator messages etc.g. relative to the pick or place position. connected to the different stations. for error checking. Such user routines are grouped in three main groups according to when they are called in the pallet cycle. the approach direction may be individually defined per pick or place position.we will delete 43 . Movements. i. pallet cycle. For each separate product individual handling speeds and load data are used.cadfamily. to order the next products on the feeder. In this routine all logic for working with parallel and simultaneous pallet cycles must be coded by the system integrator.com 44 Product Specification RobotWare for BaseWare OS 3. but which must be written by the system integrator for specific installations.A system module holding different operator dialogues.if tort to your rights.1 The document is for study only. user routines including communication with external equipment etc.Product menu gives access to the information related to the different types of product: regular products. These screens allow the following functions to be configured: . These are: .: PAL_USRR.sys PAL_DYN. which may be called from the main routine in order to change or check pallet cycles or to handle error situations.sys Modules and code not included in PalletWare In addition to the modules listed above.sys PAL_SCR. .Option ScreenViewer. including the main routine.sys Templates to be completed by the system integrator concerning work object data. including code required for operator messages.we will delete . the tool information.The “main” module. . PalletWare system modules PalletWare consists of a number of system modules as listed below. PalletWare Kernel: PAL_EXE. empty pallets.sys PAL_CYC.please inform us.sys Generated from PalletWizard: PAL_CELL. the pallet stations. stack stations and feeder station information.Cycles menu gives access to the current production status for the different lines. there are some modules which are not included in the PalletWare delivery.Station menu gives access to the robot default parameters. www.sys PAL_USRT.cadfamily. System requirements for option PalletWare .com EMail:cadserv21@hotmail. tool data. . error handling and product changes.User screens The user interacts with the program using menu driven screens on the teach pendant. com EMail:cadserv21@hotmail. Option Program memory Ram disk 145 kB (225 kB if memory option 403 is chosen) Remark Base system 335 kB 80 kB/task (including task 1) 20 kB 125 kB Multitasking Advanced Functions GlueWare 30 kB Including Advanced Functions Including Multitasking with two spotware tasks (one process and one supervision task). All the figures are approximate. Options not mentioned have no or small memory consumption (less than 10 kB). Including Multitasking with five spotware tasks (four process and one supervision task).0 MB) Other software options reduce the available program memory as follows.0 MB (ram disk=4. Including Multitasking with two spotware tasks (one process and one supervision task).1 Available memory The available user memory for the different memory options is as follows: Extended memory Total memory Program memory without options Standard 8+8=16 MB (option 402) 2.cadfamily.we will delete 45 . SpotWare 370 kB 55 kB SpotWare Plus 390 kB 75 kB SpotWare Plus 730 kB 75 kB Load Identification and Collision Detection 80 kB 40 kB www.please inform us.com 3.1 Product Specification RobotWare for BaseWare OS The document is for study only.5 MB) +8 MB 8+16=24 MB (option 403) 6.Available memory 5 Memory and Documentation 5.5 MB (ram disk=0.if tort to your rights. with step by step instructions on how to operate and program the robot. www. a description of the installation of the robot. The Product Specification is included. The other languages are also delivered and can be installed. This manual also includes a chapter called Basic Operation.2 Teach Pendant Language The robot is delivered with the selected language installed. . a description of the programming language.1 The document is for study only. a MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the instruction (marked with ‘*’) and 168 bytes if a named robtarget is used.3 Robot Documentation A complete set of documentation consisting of: . which is an introduction to the basic operation and programming of the robot. the RAPID Reference Manual and parts of the Product Manual will be in English.Teach pendant language For RAPID memory consumption.com 46 Product Specification RobotWare for BaseWare OS 3.User’s Guide. the CONST declaration of the named robtarget consumes an additional 280 bytes. 5. As an example.please inform us. . If the Danish language is chosen. and is suitable as a tutorial.if tort to your rights. 5.cadfamily. maintenance procedures and troubleshooting. In the latter case.we will delete .com EMail:[email protected] Manual. see the RAPID Developer’s Manual.RAPID Reference Manual. .......................................................... 12 11 Risks Associated with Live Electric Parts ......................................................................... 10 8 Safety Risks Related to End Effectors...................................... 4 5 Safe Working Procedures ............please inform us............................................................................................. 5 7 Safety Functions ......................................................3 Mode selection using the operating mode selector...................................................................................................................................................................................... 11 10 Risks during Installation and Service .................1 The safety control chain of operation ....................................................6 General Mode Safeguarded Stop (GS) connection............. 4 4 Definitions of Safety Functions .......Safety CONTENTS Page 1 General ...................................................3 Pneumatic/hydraulic systems ... 5 6 Programming. 13 13 Limitation of Liability.............................................................. 11 8...............................................................................................com Product Manual The document is for study only......................................................2 Tools/workpieces .....................cadfamily...................................8 Limiting the working space ........................................................................................................ 14 www................................................................1 Gripper..........................................................................................................................................................4 Enabling device ................................ 7 7.............................................. 10 7................................................................... 5 5..................................................................... 10 7................... 8 7...........9 Supplementary functions ................................................................................................if tort to your rights.............. 7 7...2 Emergency stops........................... 8 7................................................................................... 14 14 Related Information................5 Hold-to-run control...........................................................1 Introduction ........ 9 7.......................we will delete 1 .......................................................................... 3 2 Applicable Safety Standards .......................................................................... 3 3 Fire-Extinguishing............... 3 1........................................... Testing and Servicing ........................................................................................................................................................1 Normal operations ................... 11 9 Risks during Operation Disturbances..........7 Automatic Mode Safeguarded Stop (AS) connection ...... 6 7.............................................................. 6 7... 13 12 Emergency Release of Mechanical Arm ................................. 11 8......... 11 8......................................................................com EMail:cadserv21@hotmail......................................................... com 2 Product Manual The document is for study only.we will delete .cadfamily.if tort to your rights.Safety www.com EMail:[email protected] inform us. cadfamily.if tort to your rights. e. 2 Applicable Safety Standards The robot is designed in accordance with the requirements of ISO10218. Users’s Guide and Product Manual. described in applicable documents.we will delete 3 .1 Introduction Apart from the built-in safety functions. nor does it cover all peripheral equipment.com Product Manual The document is for study only. 1992. the robot is also supplied with an interface for the connection of external safety devices. which can influence the safety of the total system.g. such as reduced speed. install and operate a complete system. People who work with robots must be familiar with the operation and handling of the industrial robot.06-1992 stipulations. Via this interface. In the Product Manual/Installation and Commissioning. Jan. the complete system has to be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. instructions are provided for connecting safety devices between the robot and the peripheral equipment. The robot also fulfils the ANSI/RIA 15. Industrial Robot Safety.please inform us. 1. The diskettes which contain the robot’s control programs must not be changed in any way because this could lead to the deactivation of safety functions. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.com EMail:[email protected] Safety 1 General This information on safety covers functions that have to do with the operation of the industrial robot. The information does not cover how to design. www. an external safety function can interact with other machines and peripheral equipment. To protect personnel. Enabling device – ISO 11161. 3. In any other position. Safety stop – ISO 10218 (EN 775).com EMail:cadserv21@hotmail. Reduced speed – ISO 10218 (EN 775). stops all moving parts and removes power from other dangerous functions controlled by the robot. However.3 When a safety stop circuit is provided. 3.Safety 3 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).2.if tort to your rights.10. 4 Definitions of Safety Functions Emergency stop – IEC 204-1.2. removes drive power from robot axis actuators.7 A condition which overrides all other robot controls. if only the power to the machine actuators is reset.we will delete . Hold-to-run control – ISO 10218 (EN 775). this should not suffice to initiate any operation.4.4 A manually operated device which. 3.2.7 A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released.cadfamily. 3.17 A single. 6. www. each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit. allows hazardous functions but does not initiate them. selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot. It is necessary to reset the power to the machine actuators before any robot motion can be initiated. Interlock (for safeguarding) – ISO 10218 (EN 775).please inform us.8 A function that interconnects a guard(s) or a device(s) and the robot controller and/or power system of the robot and its associated equipment. hazardous functions can be stopped safely. when continuously activated in one position only.com 4 Product Manual The document is for study only. Testing and Servicing The robot is extremely heavy and powerful. Operators must also be aware of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without warning. at any time.com EMail:cadserv21@hotmail. • The robot’s speed is limited to max. the applicable safety regulations of the country concerned must be observed.cadfamily. 5. The position 100% – full speed – may only be used by trained personnel who are aware of the risks that this entails. Operators must be aware of the fact that the robot can make unexpected movements.please inform us. the enabling device must be released as soon as there is no need for the robot to move. When entering into the robot’s safeguarded space. Do not change “Transm gear ratio” or other kinematic parameters from the teach pendant or a PC. This will affect the safety function Reduced speed 250 mm/s. www.com Product Manual The document is for study only.if tort to your rights.1 Normal operations All normal operations in automatic mode must be executed from outside the safeguarded space. even at low speed. No safety device or circuit may be modified. A pause (stop) in a pattern of movements may be followed by a movement at high speed. bypassed or changed in any way.we will delete 5 .Safety 5 Safe Working Procedures Safe working procedures must be used to prevent injury. If work must be carried out within the robot’s work envelope. • The programmer must always take the teach pendant with him/her when entering through the safety gate to the robot’s working space so that no-one else can take over control of the robot without his/her knowledge. The enabling device must never be rendered inoperative in any way. • During programming and testing. This should be the normal position when entering the working space. 250 mm/s (10 inches/s) when the operating mode selector is in position < 250 mm/s. 6 Programming. the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. K1 K2 Drive Unit M K1 K2 Interlocking EN RUN & Man1 + LIM1 ES1 GS1 TPU En1 AS1 Auto1 LIM2 External contactors ES2 GS2 & Man2 + TPU En2 AS2 Auto2 The status of the switches is indicated by LEDs on top of the panel module in the control cabinet and is also displayed on the teach pendant (I/O window).com EMail:[email protected]. the robot always reverts to MOTORS OFF mode.Safety 7 Safety Functions 7. The time limit for the central two channel cyclic supervisions of the safety control chain is between 2 and 4 seconds.1 The safety control chain of operation The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode.com 6 Product Manual The document is for study only.we will delete . After a stop. MOTORS ON mode means that drive power is supplied to the motors.please inform us. modified or changed in any other way. the switch must be reset at the unit which caused the stop before the robot can be ordered to start again. www. The safety chains must never be bypassed. Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode. If any contact in the safety chain of operation is open.if tort to your rights. MOTORS OFF mode means that drive power is removed from the robot’s motors and the brakes are applied. must be selected whenever anyone enters the robot’s safeguarded space. No-one may enter the robot’s safeguarded space. are characterised by different modes. light curtains. and all safety arrangements. < 250 mm/s or 100%.) can be connected to the safety chain by the user (see Product Manual/Installation and Commissioning). such as emergency stops.if tort to your rights. The automatic mode safeguarded space stop (AS) function is not active in this mode. speed is 250mm/s 100% .Safety 7. etc. are active..com EMail:cadserv21@hotmail. www.com Product Manual The document is for study only. Before switching to MOTORS ON mode again. using Hold-to-run control. laid down in accordance with ISO/DIS 10218. the operating mode selector is switched to . Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the teach pendant. selected by means of control devices and with clear-cut positions.cadfamily. External emergency stop devices (buttons. establish the reason for the stop and rectify the fault.max. Before commissioning the robot. all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation. One automatic and two manual modes are available: Manual mode: < 250 mm/s . must be easily accessible from outside the safeguarded space. In automatic mode. gates. etc. such as doors. They must be connected in accordance with the applicable standards for emergency stop circuits. if 100% is selected. 7. All controls. Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows: • Set the operating mode selector to <250 mm/s • Programs can only be started using the teach pendant with the enabling device activated. light beams and sensitive mats. The robot must be operated using the teach pendant and.3 Mode selection using the operating mode selector The applicable safety requirements for using robots.2 Emergency stops An emergency stop should be activated if there is a danger to people or equipment.we will delete 7 . the control panel and control cabinet.please inform us.full speed Automatic mode: The robot can be operated via a remote control device The manual mode. com 8 Product Manual The document is for study only. www. 7. 7. For “Hold-to-run control”. the robot changes to the MOTORS ON mode. If the enabling device is reactivated. the robot can be set to the MOTORS ON mode by depressing the enabling device on the teach pendant.please inform us.5 Hold-to-run control This function is always active when the operating mode selector is in the MANUAL FULL SPEED position. When the enabling device is released. • Programs can only be started using the teach pendant with the enabling device activated.if tort to your rights. This is a safety function designed to prevent the enabling device from being rendered inactive.we will delete . These functions should be wired and interlocked in accordance with the applicable safety instructions and the operator must always be outside the safeguarded space. the drive power to the motors is switched off. .Safety Testing at full speed Robot movements at programmed speed can be carried out as follows: • Set the operating mode selector to 100%. It is possible to set a parameter to make this function active also when the operating mode selector is in the MANUAL position. Should the robot revert to the MOTORS OFF mode for any reason while the enabling device is depressed. the Hold-to-run button must be activated. The 100% mode may only be used by trained personnel. the latter must be released before the robot can be returned to the MOTORS ON mode again. Releasing the button stops program execution. Automatic operation Automatic operation may start when the following conditions are fulfilled: • The operating mode selector is set to • The MOTORS ON mode is selected.com EMail:cadserv21@hotmail. Either the teach pendant can be used to start the program or a connected remote control device.cadfamily.4 Enabling device When the operating mode selector is in the MANUAL or MANUAL FULL SPEED position. The applicable laws and regulations of the countries where the robot is used must always be observed. the brakes are applied and the robot reverts to the MOTORS OFF mode. Safety When the Hold-to-run control is active. It is possible to change execution mode when the Hold-to-run button is released and then continue the program execution with the new execution mode. 7. Here is a detailed description of how to execute a program in Hold-to-run control: • Activate the enabling device on the teach pendant.if tort to your rights. To reset to MOTORS ON mode. the sequence described above must be repeated from the beginning.FWD (one instruction forwards) .e. the enabling device and the Hold-to-run button on the teach pendant must be depressed in order to execute a program. the program execution will be continued by releasing and activating the Hold-to-run button. such as light curtains.com EMail:cadserv21@hotmail. no alert box is shown. If the program execution was stopped with the Stop button on the teach pendant.6 General Mode Safeguarded Stop (GS) connection The GS connection is provided for interlocking external safety devices. This is not normally done by resetting the device itself. Releasing the button stops program execution and activating the button will start program execution again. by just activating the Hold-to-run button again. i.please inform us.Start (continuous running of the program) . light beams or sensitive mats.BWD (one instruction backwards) • Wait for the Hold-to-run alert box. The GS is active regardless of the position of the operating mode selector.cadfamily. • Activate the Hold-to-run button on the teach pendant. When this connection is open the robot changes to the MOTORS OFF mode. Now the program will run (with the chosen execution mode) as long as the Hold-torun button is pressed. the axis (axes) movements stop and the robot remains in the MOTORS ON mode. www.com Product Manual The document is for study only. When the button is released.we will delete 9 . the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. When the enabling device on the teach pendant is released. the next instruction is run by releasing and activating the Hold-to-run button. • Choose execution mode using the function keys on the teach pendant: . For FWD and BWD execution modes. a fault occurs in the peripheral equipment.com EMail:cadserv21@hotmail. etc. movement of the three wrist axes can also be limited by the computer software. for example. Movement about axes 1. Digital inputs can be used to stop programs if. 7.Safety 7. light beams or sensitive mats used externally by the system builder. For certain applications.cadfamily. This will reduce the risk of damage to the robot if it collides with external safety arrangements. www. Limitation of movement of the axes must be carried out by the user. such as light curtains. The AS is especially intended for use in automatic mode. The AS is by-passed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position.we will delete .8 Limiting the working space NOTE! Not valid for IRB 340(r). 7.com 10 Product Manual The document is for study only.if tort to your rights. such as barriers. • MotOnState/MotOffState – indicates that the robot is in MOTORS ON / MOTORS OFF mode. • Cycle_on – indicates that the robot is executing a program.9 Supplementary functions Functions via specific digital inputs: • A stop can be activated via a connection with a digital input. 2 and 3 can be limited with adjustable mechanical stops or by means of electrical limit switches.please inform us. movement about the robot’s main axes must be limited in order to create a sufficiently large safety zone. Functions via specific digital outputs: • Error – indicates a fault in the robot system. during normal program execution.7 Automatic Mode Safeguarded Stop (AS) connection The AS connection is provided for interlocking external safety devices. If the working space is limited by means of stops or switches. If necessary. • EmStop – indicates that the robot is in emergency stop state. the corresponding software limitation parameters must also be changed. • AutoOn – indicates that the robot is in automatic mode. .please inform us. Grippers must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller. safely.we will delete 11 .1 Gripper If a gripper is used to hold a workpiece.. from falling due to gravity. Care must be taken at all times. The industrial robot is a flexible tool which can be used in many different industrial applications. Shot bolts should be used to prevent tools. etc. such as milling cutters. etc. All work must be carried out professionally and in accordance with applicable safety regulations. Such an interruption may have to be rectified manually.com EMail:cadserv21@hotmail. Dump valves should be used in case of emergency.if tort to your rights.3 Pneumatic/hydraulic systems Special safety regulations apply to pneumatic and hydraulic systems. after shutdown. The pressure in pneumatic and hydraulic systems must be released before starting to repair them. 9 Risks during Operation Disturbances If the working process is interrupted. particular care must be taken.2 Tools/workpieces It must be possible to turn off tools.com Product Manual The document is for study only. 8. It should be possible to release parts by manual operation (valves). extra care must be taken due to risks other than those associated with regular operation. www. Residual energy may be present in these systems so. inadvertent loosening of the workpiece must be prevented. Gravity may cause any parts or objects held by these systems to drop.cadfamily. 8. Make sure that guards remain closed until the cutters stop rotating.Safety 8 Safety Risks Related to End Effectors 8. Remedial action must only ever be carried out by trained personnel who are familiar with the entire installation as well as the special risks associated with its different parts. • Energy. stored in the robot for the purpose of counterbalancing certain axes.we will delete .com 12 Product Manual The document is for study only. • The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner. you run the risk of being crushed by the tie rod. have to be carried out while the power supply is turned on. • Safety zones. • Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it. Light beams or sensitive mats are suitable devices. the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.com EMail:cadserv21@hotmail. • Turntables or the like should be used to keep the operator away from the robot’s working space. • Be aware of stored energy (DC link) and hot parts in the controller. or parts thereof. To prevent injuries and damage during the installation of the robot system. • Units inside the controller.if tort to your rights. i.e. In addition to the risk of being hit by moving robot parts. watch out for falling objects. in accordance with the applicable standards for the emergency stop function. • The axes are affected by the force of gravity when the brakes are released. Although troubleshooting may. the robot must be turned off (by setting the mains switch to OFF) when repairing faults. www. I/O modules. • Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. you can still injure yourself. • The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space. do not climb on the robot motors or other parts during service work. e. can be supplied with external power. must be set up in front of the robot’s working space. is dismantled.cadfamily. • When dismantling/assembling mechanical units.g. Even if the power supply for the robot is turned off. on occasion. disconnecting electric leads and disconnecting or connecting units.Safety 10 Risks during Installation and Service Never use the robot as a ladder.please inform us. • The instructions in Product Manual/Installation and Commissioning must always be followed. • Those in charge of operations must make sure that safety instructions are available for the installation in question. which have to be crossed before admittance. may be released if the robot. Special attention must be paid to the following points: • The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot. but for the bigger ones it might not be possible without a mechanical lifting device..The mains supply/mains switch . Tools.The power supply unit for the computer system (55 V AC) .The service outlets (115/230 VAC) . www.The power supply for the motors (up to 370 V DC) . 12 Emergency Release of Mechanical Arm If an emergency situation occur where a person is caught by the mechanical robot arm.com EMail:cadserv21@hotmail. and therefore manpower might not be sufficient for any robot. like an overhead crane. .com Product Manual The document is for study only. NB: Capacitors!) . 230 V AC) Tools.Safety 11 Risks Associated with Live Electric Parts Controller A danger of high voltage is associated with the following parts: . material handling devices. etc. etc. may be live even if the robot system is in the OFF position.The power supply unit for tools. material handling devices.if tort to your rights.cadfamily.The user connections for tools or other parts of the installation (see Product Manual/Installation and Commissioning.The drive unit (370 V DC) . the brake release buttons should be pressed whereby the arms can be moved to release the person.The rectifier unit (260 V AC and 370 V DC. Before releasing the brakes.we will delete 13 .Additional connections Manipulator A danger of high voltage is associated with the manipulator in: .The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. max. Power supply cables which are in motion during the working process may be damaged.please inform us. To move the arms by manpower is normally possible on the smaller robots (1400 and 2400). or special power supply units for the machining process .The power unit . secure that the weight of the arms not enhance the press force on the caught person. If power is not available the brakes are applied. Safety 13 Limitation of Liability The above information regarding safety must not be construed as a warranty by ABB Robotics that the industrial robot will not cause injury or damage even if all safety instructions have been complied with. 14 Related Information Described in: Installation of safety devices Changing robot modes Limiting the working space Product Manual .Installation and Commissioning User’s Guide .we will delete .Installation and Commissioning www.com 14 Product Manual The document is for study only.cadfamily.Starting up Product Manual .com EMail:[email protected] inform us.if tort to your rights. EN 60204-1 accepts one channel circuit without monitoring. Part 2: Industrial environment Radiated emission enclosure Conducted emission AC Mains EMC. fixed / moveable guards Safety of machinery.we will delete 3HAB 3585-1 09 . 91/368 EEC. The original document (in English) with the serial number declare that the industrial robot Herewith we on it is supplied together with the robot IRB 1400 IRB 4400 IRB 2000 IRB 6000 IRB 2400 IRB 6400 IRB 3000 IRB 6400C IRB 3400 IRB 640 Declaration by the manufacturer manufactured by ABB Robotics Products AB 721 68 Västerås. two-hand control device Safety of machinery.cadfamily. Part 2: Industrial environment Electrostatic discharge immunity test Radiated.of pages APPROVED Tillverkardeklaration Document No AT IO N 1 Rev. Label with serial number is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the directive.com ABB Robotics Products The document is for study only. 970904 Approved by. electromagnetic field immunity yest Radeated electromagnetic field from digital radio telephones. Generic immunity standard.date SEROP/KM Take over department R Technical Provisions Page 1 K-G Ramström. ind. emergency stop Safety of machinery. safety related parts of the control system EMC.5. emergency stop equipment Safety of machinery.4. temperatures of surfaces Safety of machiney.please inform us. Applied harmonised standards in particular: We reserve all rights in this document and in the information contained therein. ergonomic design principles Robot safety Electrical equipment for industrial machines 1) Safety of machinery. use or disclosure to third parties without express authority is strictly forbidden. where the demands for redundancy is found. Sweden with serial No. by machinery directive 89/392/EEC Annex II B as defined This is only a translation of the customs declaration. technical principles/specifications. immunity test IN FO Title H Hvittfeldt. M No. Generic emission standard. FO R EN 292-1 EN 292-2 EN 418 EN 563 EN 614-1 EN 775 EN 60204 prEN 574 prEN 953 prEN 954-1 EN 50081-2 EN 55011 Class A EN 55011 Class A EN 50082-2 EN 61000-4-2 EN 61000-4-3 ENV 50204 EN 61000-4-4 ENV 50141 Safety of machinery. © ABB Robotics Products AB Prepared Responsible department O N LY 1) There is a deviation from the extra demand for only electromechanical components on emergency stop of category 0 in paragraph 9. Reproduction. radio-frequency. 970905 Product Design Responsible Status Declaration by the manuf. basic terminology Safety of machinery.if tort to your rights.To the User “Declaration by the manufacturer”. instead the design is made to comply with category 3 according to EN 954-1. immunity test Electrical fast transient/burst immunity test Conducted disturbences induced by radio-frequency fields.2. www.com EMail:cadserv21@hotmail. com The document is for study only.if tort to your rights.please inform us.www.cadfamily.we will delete .com EMail:cadserv21@hotmail. if tort to your rights.please inform us.cadfamily.ABB ROBOTICS PRODUCTS AB Robot type: For RAC: Revision: RAC Ref no: CONFIGURATION LIST Manufact order no: Serial no: Sales order no: Tested and approved: MANIPULATOR: Date Name CONTROL SYSTEM: User To the ROBOT SYSTEM: Configuration List is an individual specification of the robot The system delivered regarding configuration and extent.com The document is for study only.com EMail:cadserv21@hotmail. Date Delivery from factory: On delivery.we will delete . Delivery to customer: Acceptance by customer: Customer information: Customer: Address: OPTIONS/DOCUMENTATION QTY OPTION/PARTNO REVISION DESCRIPTION www. the complete document is placed in the robot controller. www.com The document is for study only.please inform us.com EMail:[email protected] will delete .cadfamily.if tort to your rights. ................................................com Product Manual The document is for study only.......................................................................2 Controller ............................... 18 5..........................2 MOTORS ON and MOTORS OFF modes ................................. 11 3 Servo System............................................................................ 18 5....if tort to your rights.......... 15 5 Safety System............please inform us......................com EMail:cadserv21@hotmail........................................ 17 5..... 3 1............we will delete 1 .......................................................................................................................................................7 Monitoring............................................ 13 3........ 13 3............................... 19 5................................................. 21 www.......................................................................................................................................................................................5 ENABLE.. 13 3.... 3 1................................. 19 6 External Axes............................4 Limitation of velocity.......................................................................................2 Regulation................................................................................... 13 3........................................................................................... 14 4 I/O System..................3 Controlling the robot. 19 5................................................................................................................ 7 1..................................................................................1 Principle function ........ 8 2 Computer System .......................................1 Manipulator .........................................................................................................................................................6 24 V supervision.................................................3 Electronics unit .......................................System Description CONTENTS Page 1 Structure .............................................................................1 The chain of operation ......3 Safety stop signals ................... 17 5.............................................................................................................................. 19 5...................................................................................................................cadfamily..........4 Overload protection................................................. System Description CONTENTS Page www.com EMail:[email protected] will delete .com 2 Product Manual The document is for study only.if tort to your rights.please inform us. System Description Structure 1 Structure The robot is made up of two main parts. 1.2.1 Manipulator It is equipped with maintenance-free.please inform us. described in sections 1. The following figures shows the various ways in which the different manipulators moves and its component parts. Product Manual www.cadfamily. The time is configurabble for the user.if tort to your rights.we will delete 3 .com The document is for study only.1 and 1. Motor axis 5 Motor axis 6 Axis 3 Axis 4 Axis 5 Axis 6 Motor axis 4 Upper arm Axis 2 Motor axis 1 Lower arm Motor axis 2 Motor axis 3 Axis 1 Base Figure 1 The motion patterns of the IRB 1400 and IRB 140. The brakes lock the motors when the robot is inoperative for more than 1000 hours.com EMail:cadserv21@hotmail. manipulator and controller. AC motors which have electromechanical brakes. Lower arm Motor unit and gearbox axis 2 Axis 5 Upper arm Axis 4 Motor axis 4 Motor axis 5 Motor axis 6 Axis 3 Axis 6 Lower arm Axis 2 Motor axis 1 Motor axis 3 Motor axis 2 Axis 1 Base Figure 3 The motion patterns of the IRB 4400.if tort to your rights.we will delete .cadfamily.please inform us. 4 Product Manual www.com The document is for study only.Structure System Description Motor unit axis 4 Motor unit axis 5 Motor unit axis 6 Axis 4 Axis 3 Upper arm Axis 6 Axis 5 Motor unit and gearbox axis 1 Axis 2 Motor unit and gearbox axis 3 Axis 1 Base Figure 2 The motion patterns of the IRB 2400.com EMail:cadserv21@hotmail. Axis 3 Upper arm Motor axis 6 Axis 6 Axis 2 Motor axis 2 Motor axis 3 Lower arm Motor axis 1 Axis 1 Figure 5 The motion patterns of the IRB 640.com The document is for study only.cadfamily.we will delete 5 .please inform us.System Description Structure Axis 3 Upper arm Motor axis 4 Axis 4 Axis 5 Motor axis 6 Axis 6 Motor axis 1 Motor axis 3 Axis 1 Axis 2 Motor axis 2 Motor axis 5 Lower arm Base Figure 4 The motion patterns of the IRB 6400.if tort to your rights. Product Manual www.com EMail:cadserv21@hotmail. Axis 2 Axis 3 Y Axis 2 Upper arm (x3) Axis 3 Motors encapsulated Base box Bars (x3) Axis 1 Swivel X Z Axis 4. telescopic shaft (option) Figure 7 The motion patterns of the IRB 340.Structure Motor 1(X)-axis System Description Motor 3(Z)-axis Motor 2(Y)-axis Motor 4(C)-axis 2(Y)-axis 3(Z)-axis 4(C)-axis 1(X)-axis Figure 6 The motion patterns of the IRB 840/A.cadfamily.we will delete .com The document is for study only.com EMail:[email protected] inform us.if tort to your rights. 6 Product Manual www. System Description Structure 1.2 Controller The controller. Figure 8 shows the location of the various components on the cabinet.com The document is for study only.if tort to your rights. which contains the electronics used to control the manipulator and peripheral equipment.com EMail:cadserv21@hotmail. Product Manual www. Teach pendant Operator’s panel Mains switch Disk drive Manipulator connection Figure 8 The exterior of the cabinet showing the location of the various units.cadfamily. is specifically designed for robot control.please inform us. and consequently provides optimal performance and functionality.we will delete 7 . are gathered together inside the controller. contactors.com The document is for study only. DC-link. • Supply unit – 4 regulated and short-circuit-protected output voltages. containing circuits for network and field bus communication. Drive system: • DC link – converts a three-phase AC voltage to a DC voltage. • Memory board – contains extra RAM memory. which is located inside the manipulator. main switch. • Main computer board – contains 8 MB RAM memory and the main computer. transformer.if tort to your rights. and supply unit.Structure System Description 1. 8 Product Manual www.please inform us. a second control cabinet is used. there are three sizes.com EMail:cadserv21@hotmail. apart from the serial measurement board. • Drive module – controls the torque of 2-3 motors. which controls the entire robot system.3 Electronics unit All control and supervisory electronics. but no computer unit. 8 and 16 MB. The computer unit (supply unit + board backplane) comprises the following parts: • Robot computer board – contains computers used to control the manipulator motion and I/O communication.we will delete Optional board Memory board . drive module(s). When the maximum capacity for external axes is utilized.cadfamily. Drive module 3 Drive module 2 Drive module 1 DC link Robot computer Main computer Optional board Supply unit Transformer Figure 9 The location of the electronics boards and units behind the front door. • Optional boards – Communication boards. The external axes cabinet comprises AC connection. com The document is for study only.we will delete 9 . Product Manual www. • Serial measurement board (in the manipulator) – gathers resolver data and transfers it serially to the robot computer board. analog signals or field buses.please inform us.if tort to your rights.cadfamily. • Lithium batteries for memory back-up. The serial measurement board is battery-backed so that the revolution information cannot be lost during a power failure.System Description Structure Lithium batteries I/O units (x4) AC connection Panel unit Motors On and brake contactors Floppy disk Figure 10 The location of units under the top cover. which allows the units to be positioned close to the process. • I/O units – enables communication with external equipment by means of digital inputs and outputs.com EMail:cadserv21@hotmail. I/O units can alternatively be located outside the cabinet. Communication with robot data is implemented via a stranded wire CAN bus. • Panel unit – gathers and coordinates all signals that affect operational and personal safety. cadfamily.we will delete .com EMail:[email protected] tort to your rights.com The document is for study only.Structure System Description 10 Product Manual www.please inform us. we will delete 11 . .if tort to your rights. The computers comprise: . The computers are the data processing centre of the robot.please inform us.com EMail:cadserv21@hotmail. the world around and the axis computer that regulates the velocity of the robot axes.Main computer board – contains the main computer of the robot and controls the entire robot. To find out where the various boards are located.com The document is for study only. execute and store a robot program. Main computer board Main computer Memory board Robot computer board Axis computer I/O computer Network I/O computer Teach pendant Drive units Serial measurement board Disk drive I/O units Figure 11 The interfaces of the computer system. They also contain functions for coordinating and regulating the axis movements.cadfamily.System Description Computer System 2 Computer System The computer system is made up of three computers on two circuit boards. Product Manual www.Robot computer board – contains the I/O computer which acts as a link between the main computer. see Electronics unit on page 8. Figure 11 shows how the computer system communicates with the other units. They possess all the functions required to create. com EMail:[email protected] inform us.com The document is for study only.cadfamily.if tort to your rights.Computer System System Description 12 Product Manual www.we will delete . The serial measurement board receives resolver data from a maximum of six resolvers and generates information on the position of the resolvers. 3. The servo function comprises: • Digital regulation of the poses.cadfamily. 3. In this way.we will delete 13 . See Figure 12.1 Principle function The servo system is a complex system comprising several different interacting units and system parts – both hardware and software. Product Manual www. are amplified to the working voltage of the motors.3 Controlling the robot An digital current reference for two phases is calculated on the basis of the resolver signal and a known relationship between the resolver angle and rotor angle.2 Regulation During execution.if tort to your rights.com The document is for study only.com EMail:[email protected] Description Servo System 3 Servo System 3. new references are given for the pose and velocity of the robot. The third phase is created from the other two. new data on the poses of the robot axes is continuously received from the serial measurement board. three voltage references are returned which. The current of the phases is regulated in the drive unit in separate current regulators. • Synchronous AC operation of the robot motors. velocity and motor current of the robot axes. by pulse-modulating the rectifier voltage.please inform us. After it has been compared and amplified. The system also contains a model of the robot which continuously calculates the optimal regulator parameters for the gravitation. This data is input into the position regulator and then compared with previous position data. the moment of inertia and the interaction between axes. please inform us. 14 Product Manual www.we will delete .cadfamily.4 Overload protection PTC resistance is built into the robot motors to provide thermal protection against overloads. The PTC sensors are connected to an input on the panel unit which is sensitive to resistance level and which check that low resistance is maintained. In the event of an overload. Computer Rotor position Torque reference Serial measurement board DC link Drive Unit M R AC OPERATION DC link TORQUE reference M CURRENT ESTIMATOR + PWM + M PWM ROTOR POSITION + CURRENT REGULATOR PWM M U W + M + MAIN CIRCUITS V Figure 12 System structure for AC operation. 3.Servo System System Description The following diagrams outline the system structure for AC operation as well as the fundamental structure of the drive unit. all motors are switched off.if tort to your rights.com The document is for study only.com EMail:cadserv21@hotmail. The robot computer checks the motors for overloading at regular intervals by reading the panel unit register. if tort to your rights.please inform us.com EMail:cadserv21@hotmail. Communication board Product Manual www. Main computer VME bus I/O computer Teach pendant Disk drive General Serial ports RS 422 RS 232 SIO2 SIO1 Distributed I/O bus CAN/ DeviceNet Customer connections 16 16 I/O unit(s) I/O I/O I/O Field bus slave unit(s) Panel unit Safety signals Ethernet Figure 13 Overview of the I/O system.com The document is for study only.cadfamily.System Description I/O System 4 I/O System Communicates with other equipment using digital and analog input and output signals.we will delete 15 . if tort to your rights.I/O System System Description 16 Product Manual www.please inform us.com The document is for study only.com EMail:[email protected] will delete .cadfamily. In any of the MANUAL modes. To return the robot to MOTORS ON mode. the enabling device on the teach pendant overrides the AUTO STOP. which is active in the AUTO operating mode.cadfamily.1 The chain of operation The emergency stop buttons on the operator’s panel and on the teach pendant and external emergency stop buttons are included in the two-channel chain of operation. The safeguarded stop GENERAL STOP is active in all operating modes and is connected by the user. 5. The aim of these safeguarded stop functions is to make the area around the manipulator safe while still being able to access it for maintenance and programming. If an error is detected. Product Manual www.com The document is for study only. As long as these two chains differ. the two identical chains of switches must be closed. Figure 14 below illustrates an outline principal circuit with available customer contacts. the robot will remain in the MOTORS OFF mode. can be connected by the user. the power supply to the motors is switched off and the brakes engage.com EMail:[email protected] Description Safety System 5 Safety System The robot’s safety system is based on a two-channel safety circuit that is continuously monitored.if tort to your rights. teach pendant unit GS = General mode safeguarded space Stop ES = Emergency Stop Figure 14 Outline diagram of one of the safety circuits.we will delete 17 .please inform us. LS Solid state switches Contactor ES 2nd chain interlock Drive unit GS & TPU En EN AS RUN M Computer commands Auto Operating mode selector Manual LS = Limit switch AS = Automatic mode safeguarded space Stop TPU En= Enabling device. A safeguarded stop. AUTO STOP. Status indication is also available on the teach pendant display. an interrupt call is sent directly from the panel unit to the robot computer to ensure that the cause of the interrupt is indicated.2 MOTORS ON and MOTORS OFF modes The principle task of the safety circuit is to ensure that the robot goes into MOTORS OFF mode as soon as any part of the chain is broken. such as when a light curtain. The LEDs are located on the upper part of the panel unit. If the safety circuit breaks. Activation is made by setting a parameter. The safety circuit can thus be broken in two places by the robot computer. when the power supply to the motors must be switched off immediately. the motor contactors drop out. Category 1 is preferred for safety analysis purposes. see below: The category 0 stop is to be used for safety analysis purposes. Topic: Controller. 5. if it is acceptable. AS and GS are connected to the two safety circuits to enable quick location of the position where the safety chain is broken. used to protect against entry into the work cell. LEDs for ES. When the robot is stopped by a limit switch. The function of the safety circuit can be described as a combination of mechanical switches and robot computer controlled relays which are all continuously monitored by the robot computer. In AUTO mode.cadfamily. it can be moved from this position by jogging it with the joystick while pressing the MOTORS ON button. at which stage the robot computer also opens the MOTORS ON relay. you can start operating again by pressing the enabling device on the teach pendant.3 Safety stop signals According to the safety standard ISO/DIS 11161 “Industrial automation systems safety of integrated manufacturing systems . The MOTORS ON button is monitored and may be depressed for a maximum of 30 seconds. the ENABLE chain will break and the ENABLE relay is opened.com EMail:[email protected] will delete .Basic requirements”. Safety stops of category 1 can be obtained by activating the soft stop (delayed stop) together with AS or GS. the mode changes to MOTORS OFF. If the circuit is OK. section System Parameters. there are two categories of safety stops. If the robot mode does not change to MOTORS OFF. you can switch the robot back on by pressing the MOTORS ON button on the operator’s panel. is passed. 5. and the robot is stopped by the brakes. When switching to MANUAL. The robot computer itself controls the last switches (ENABLE and MOTORS ON). This controlled motion stop takes place within the programmed path.Safety System System Description If any of the dual switches in the safety circuit are opened.if tort to your rights. which makes restarting easier. All the robot’s safety stops are category 0 stops as default. If the circuit is OK. the robot computer then closes the MOTORS ON relay to complete the circuit. such as when gates are used to protect against entry into the work cell. the robot computer then closes the MOTORS ON relay to complete the circuit.please inform us. see User’s Guide. 18 Product Manual www.com The document is for study only. the circuit breaks. In any of the MANUAL modes. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop. category 0 and category 1. generated in the supply unit.7 Monitoring Monitoring is carried out using both hardware and software. Then the robot’s maximum velocity is limited to 250 mm/s. the MOTORS ON contactors will drop out. and comprises the external part of the safety circuits. regulating errors and overcurrent.6 24 V supervision If the 24 V supply to the safety circuits drops out. the operating mode switch must be turned to MANUAL REDUCED SPEED position. 5. 5. including switches and operating contacts. errors in the input voltage. • In the drive unit.we will delete 19 .com The document is for study only.com EMail:cadserv21@hotmail. The following errors may be detected: All inputs from the safety circuits are linked to registers. Product Manual www.please inform us. to the panel unit. The hardware and software parts operate independently of each other. causing only one of the chains of operation to be interrupted. which allows the robot computer to monitor the status. The signal is sent through the robot computer.if tort to your rights.System Description Safety System 5.5 ENABLE ENABLE is a 24 V signal. errors in the diagnostics or servo control program. causing the motors to switch off. If an interrupt occurs in the circuit. • In the robot computer. 5. The errors that affect the Enable signal are: • In the supply unit.4 Limitation of velocity To program the robot. By means of hardware interlocking it is not possible to enter MOTORS ON without correcting the cause. the status can be read. the robot computer will detect this.cadfamily. If any of the switch functions are incorrectly adjusted. com EMail:[email protected] System System Description 20 Product Manual www.please inform us.if tort to your rights.cadfamily.com The document is for study only.we will delete . The maximum of drive units mounted inside the controller is one or two. In addition to drive units from ABB. Contains no CPU IRB Drive System 2 inside external axes cabinet Measurement System 1 Figure 15 Outline diagram. it is also possible to communicate with external drive units from other vendors. external axes. inside robot cabinet Not supplied on delivery Alt.com EMail:cadserv21@hotmail. Measurement System 2 Drive System 1.please inform us.com The document is for study only.System Description External Axes 6 External Axes NOTE! Not valid for IRB 340(r).if tort to your rights. See Product Specification RobotWare for BaseWare OS 3.we will delete 21 . see Figure 15.cadfamily. mounted either inside the controller or outside in a separate enclosure. Not supplied on delivery Product Manual www. External axes are controlled by drive units.1. depending on robot type. com EMail:[email protected] inform us.External Axes System Description 22 Product Manual www.cadfamily.com The document is for study only.we will delete .if tort to your rights. . 31 2..............1 Stability / risk of tipping..................7 Manually engaging the brakes........... 12 2..............cadfamily......... 7 2........................................ 10 2....................3... 29 2..................................2 Controller ........................................................................................................................................................................ 30 2.......................if tort to your rights........................................................................ 28 2................ 11 2........................1 Connection on left-hand side of cabinet ......................................please inform us............................5................................... 3 Assembling the robot.................. 12 2...........................14............................................................................2 IRB 2400/10............................................... 2 Turning the manipulator (inverted suspension application) ...................................... 13 2......................................... 22 2.................11 Loads.............we will delete 1 ............................................................................6..... 18 2...................................................................................................6 Amount of space required....... 26 2..............................1 Stiffness............................................................................................................ 29 2....................... 5 2 On-Site Installation .8................12.................15 Inspection before start-up ................................................................................................................................................................8............................................... 25 2.3 Checking the calibration position ............ 33 2..... 16 2.......................... 5 1.................................................com Product Manual IRB 2400 The document is for study only.....................................16...2 Axis 2 ........................................................................................................................................................................... 32 2...1 Manipulator.......................................... 17 2...................3..................16.....................................................2 Updating the revolution counter ............................................ 29 2........................................14..16 Start-up .......9 Unlimited working range axis 4 ... 5 1..5 Stress forces..........14 Mains power connection........8.............................................................................5................1 General .. 14 2..... 19 2...................................................................................................................................................... 24 2.............................2 Controller ..................... 11 2................. 9 2................. 12 2.........3 Axis 3 ..............................................4 Suspended mounting............................................................13 Dimensioning the safety fence ............................................com EMail:[email protected] IRB 2400L................................................................. /16............. 32 2................................................................................................................................6................................................... 30 2..............................16.......... 10 2.... 31 2...........Installation and Commissioning CONTENTS Page 1 Transporting and Unpacking .1 Manipulator.................................12 Connecting the controller to the manipulator ....... 7 2............................ 12 2......1 Lifting the manipulator............1 Connection to the mains switch .......................................................... 37 www......................8 Restricting the working space..5............................................................2 System diskettes .........................................................................................1 Axis 1 .....10 Mounting holes for equipment on the manipulator ..2 Connection via a power socket ...................................... ........com EMail:cadserv21@hotmail............................................................................................... 3.......................5 Operating the robot ....................................................................................................2 Connection to Motor On/Off contactors ..15......16..... 2........................................we will delete .............com 2 Product Manual IRB 2400 The document is for study only........................ 3.....................................................1 24 V I/O supply..............10 External customer connections..........................................5. 3........................................2 115/230 V AC supply ..12....................9........................................ 3.9......please inform us....14 External 24 V supply ......................................9..................................................................3 Interference elimination ... 3.... 3............. 3.......................3 Connection of signal lamp on upper arm (option) ......................................................12 Safeguarded space stop signals ..2 To connectors (option) .....................16.................. 3..................................7 Connection to screw terminal................................. /16 .........13......1 To screw terminal................................. 3 Connecting Signals.................................................................................................................................................... IRB 2400L .......................................2 Connections on upper arm...4 Connection to brake contactor ......................... 3....... 3..................................................................................................................2 Selecting cables ......... 3............... 3....16 Distributed I/O units ..................... 3..............3 Connection to operating mode selector ...2 3...3 3..................................15........... 3................. AD Combi I/O DSQC 327 (optional) .................4 Alternative calibration positions ....5......1 Connection of ES1/ES2 on panel unit .............13 Available voltage ..........5 Connections ..15..................................... 3...........................16....13...... 3................ 3.........................1 Signal classes..................................................................................... 3......... Sensors ......6 Customer connections on manipulator.................11 External safety relay ......1 Connections on upper arm......cadfamily........ IRB 2400/10.. 3............................ 37 37 39 39 39 40 40 41 41 41 43 48 49 50 51 52 52 52 53 56 57 57 57 57 58 58 59 59 60 61 62 62 62 63 65 67 www..15 Connection of extra equipment to the manipulator ..................................................... Connection and address keying of the CAN-bus........... 3............16........................ 3.................................................................................................................................... 3........Installation and Commissioning CONTENTS Page 2...........5 General.........................8 The MOTORS ON / MOTORS OFF circuit ................................if tort to your rights.................16........9.....................1 Delayed safeguarded space stop ......................................1 3.............................................................................................................................. 3....................................... 3.........................................4 Connection types .........................16..........................................................4 3..... Digital I/O DSQC 328 (optional)......................9 Connection of safety chains ..... 3...........................................16....................... 3...................................................................................................................................... 3............................................................... 3......................................................... 3....................................................................................... ............ 118 www.................................com Product Manual IRB 2400 The document is for study only...................................................1 RIO (Remote Input Output).... 70 3..............2 FBU........1 System diskettes ............... 106 5........................................................................................17....... 96 4............................................................. slave........ 91 3................... 79 3. 96 4................2 Easy to use kits ...........1 Serial links...............1........................................3............. 95 4..we will delete 3 ................................................................................... 84 3....... 104 5...................... 73 3..................................2 Robot delivered without software installed ........................................................................................................16.................................. 95 4......1 Installation procedure..... 89 3.... remote I/O for Allen-Bradley PLC DSQC 350 .........17......................................................................... options and IRB types......17 Field bus units....6 Analog I/O DSQC 355 (optional) . 76 3................................................. Manipulator Parameters.................... 97 4.......................... 89 3.............................................................. 99 5 External Axes................................. 105 5......................................16............................1 General....5 How to use the disk........................ SIO ......5 Configuration Files .................17.......................cadfamily......................................................................... 110 5............................................................................2 Question about used DC-links and balancing units ................................................... 104 5.........3 User designed external axes ......5.......19 External operator’s panel.................... DSQC 336......com EMail:cadserv21@hotmail............ 82 3.......... 98 4......................................4 Drive System.....................................................1 DMC-C.....................................................................3.......................................18................................ 101 5....................................................1.....................5.......................................................................................please inform us.......................................................................................................................................Installation and Commissioning CONTENTS Page 3.............................................. 98 4..................... DSQC 354 .... 93 4 Installing the Control Program.....3..2 Ethernet communication.....16....16................. 98 4.6 Saving the parameters on the Controller Parameter disk ..... 97 4.................... 95 4.............3..................8 Relay I/O DSQC 332 ..............3 Measurement System .....................................................................4 How to change language.....................1 Robot delivered with software installed......... DSQC352 ............3...........3 Profibus-DP.....if tort to your rights.................................9 Digital 120 VAC I/O DSQC 320.................................2 Calibration of the manipulator.....18.................................. 103 5.....................................................7 Encoder interface unit...........................3 Cold start..... 101 5........................2 Interbus-S.................. slave DSQC 351 ..................................................................................................... 87 3.........................18 Communication .......... 82 3.............. we will delete .cadfamily.please inform us.if tort to your rights.Installation and Commissioning CONTENTS Page www.com EMail:[email protected] 4 Product Manual IRB 2400 The document is for study only. When you have unpacked the robot. When air transport is used. as this could cause the manipulator to tip over. Never work with the original diskettes.please inform us. the robot must be located in a pressure-equalized area. When you have made copies. These are found in separate sections in the User’s Guide and Product manual. the manipulator is not stable in the whole working area. +5° to +50 ° C (manipulator) +5° to + 52° C (controller) Max. axis 2 must be bent backwards 30° and axis 3 must be moved down to a position against the rubber stops on axis 2. Operating conditions: Ambient temperature Relative humidity Storage conditions: If the equipment is not going to be installed straight away. fixed to the shelf for the teach pendant. Product Manual IRB 2400 www. should be copied (in a PC) before they are used. The net weight of the manipulator is approximately: 380 kg The control system weighs approximately: 240 kg. 1. When the arms are moved. read the safety regulations and other instructions very carefully. Whenever the manipulator is transported. The installation shall be made by qualified installation personnel and should conform to all national and local codes.1 Stability / risk of tipping When the manipulator is not fastened to the floor and standing still.cadfamily. it must be stored in a dry area at an ambient temperature between -25°C and +55°C.we will delete 5 . 95% at constant temperature 1.if tort to your rights. care must be taken so that the centre of gravity is not displaced. Do not store diskettes inside the controller due to the high temperatures there.com EMail:[email protected] The document is for study only.Installation and Commissioning Transporting and Unpacking 1 Transporting and Unpacking NB: Before starting to unpack and install the robot. store the originals in a safe place. check that it has not been damaged during transport or while unpacking.2 System diskettes The diskettes in the box. cadfamily.if tort to your rights.please inform us.we will delete .com The document is for study only.com EMail:[email protected] and Unpacking Installation and Commissioning 6 Product Manual IRB 2400 www. Installation and Commissioning On-Site Installation 2 On-Site Installation 2. 2 Turning the manipulator (inverted suspension application) .please inform us.com EMail:cadserv21@hotmail. The brakes must be manually released to make it possible to alter the positions of the arms.cadfamily. 14o to get balance. Recommended lifting sling: Type: KDBK 7-8 L=2 m Load at 90o= 380 kg Move the lower arm backwards approx. 14° Figure 1 Lifting the manipulator using a traverse crane. See also chapter 2.if tort to your rights. see Chapter 2.1 Lifting the manipulator The best way to lift the manipulator is to use lifting straps and a traverse crane. Attach the straps to the special eye bolts on the gear boxes for axes 2 and 3 (see Figure 1).com The document is for study only.7 Manually engaging the brakes. The lifting strap dimensions must comply with the applicable standards for lifting.we will delete 7 . Never walk under a suspended load. Product Manual IRB 2400 www. we will delete . Min.com The document is for study only. 60° A A A-A Figure 2 The maximum angle between the lifting straps when lifting the controller.if tort to your rights.com EMail:cadserv21@hotmail. A fork lift truck must be used instead. lifting devices must not be used.cadfamily.On-Site Installation Installation and Commissioning Use the lifting devices on the cabinet or a fork lift when lifting the controller (see Figure 2). If the controller is supplied without its top cover.please inform us. 8 Product Manual IRB 2400 www. Lifting beam min. 520 63 Nm 63 Nm 200 Nm appr.if tort to your rights. Product Manual IRB 2400 www.we will delete 9 .com EMail:cadserv21@hotmail. the manipulator should be positioned according to Figure 3. 2 Turning the manipulator (inverted suspension application) A special tool is recommended when the manipulator is to be turned for inverted mounting (ABB article number 3HAB 8961-1).cadfamily. R=1090 65o 135o appr. The manipulator is delivered in this position.com The document is for study only. R=1090 Figure 3 Manipulator with mounted turning tool.Installation and Commissioning On-Site Installation 2. When the special tool is mounted. 960 Fork lift appr.please inform us. to allow the same robot to be re-mounted without program adjustment.5 Stress forces . follow the general instructions for expansion-shell bolts.cadfamily. The levelness requirement of the surface is as follows: 0.no. Two guide sleeves (art. 10 Product Manual IRB 2400 www. T= 3 mm When bolting a mounting plate or frame to a concrete floor.039 -0 H8 0.com The document is for study only.if tort to your rights.5 Z = centre line axis 1 280 D=18. oiled screws). 2151 0024-169) can be added to the rear bolt holes.On-Site Installation 2.1 Manipulator Installation and Commissioning The manipulator must be mounted on a level surface with the same hole layout as shown in Figure 4. Note that washers must be used! Suitable washers: D= 17 / 30 . The screw joint must be able to withstand the stress loads defined in Chapter 2.3.5 Use M16 (x3) screws to bolt the manipulator down (tightening torque 190 Nm.A View from the bottom of the base (footprint) Figure 4 Bolting down the manipulator.25 (2X) Section A .com EMail:[email protected] (2x) A A The same dimensions 260 260 210 Z Y 48 20 D=35 +0. X D=18.we will delete .please inform us. 3 Assembling the robot 2. See also Chapter 2. Product Manual IRB 2400 www. If the robot is converted from suspended to floor-mounted configuration. so that optimum performance can be achieved.com EMail:cadserv21@hotmail. (They are supplied loose together with the robot for floor-mounting). before assembling the controller.we will delete 11 .com The document is for study only.6 Amount of space required. remove the plugs. make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections.4 Suspended mounting The method for mounting the manipulator in a suspended position is basically the same as for floor mounting.Installation and Commissioning On-Site Installation 2. 2522 2101-9. 720 400 2. With inverted installation. part no.3. There are two holes in the bottom plate which must be sealed with plastic plugs.2 Controller Secure the controller to the floor using M12 screws (as shown in the hole layout below).please inform us.if tort to your rights. Figure 5 Conversion of robot from floor-mounted to suspended configuration. This applies only to suspended configuration.cadfamily. 4100 ± 1900 N ± 4000 Nm ± 900 Nm Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 6). standing Force z. 2. standing Force z.4100 ± 1100 N ± 3000 Nm ± 450 Nm Max. load (Emergency stop) ± 2600 N 4100 ± 1900 N .if tort to your rights. suspended Torque xy Torque z ± 1700 N 4100 ± 1100 N . /16 Endurance load (In operation) Force xy Force z.4100 ± 1400 N ± 3400 Nm ± 550 Nm Max.1 Stiffness The stiffness of the foundation must be designed to minimize the influence on the dynamic behaviour of the robot.5.please inform us.5. suspended Torque xy Torque z ± 2000 N 4100 ± 1400 N . 12 Product Manual IRB 2400 www.2 IRB 2400/10. 2.cadfamily. TuneServo can be used for adapting the robot tuning to a non-optimal foundation.5 Stress forces 2.4100 ± 1400 N ± 3400 Nm ± 900 Nm Fxy and Mxy are vectors that can have any direction in the xy plane (see Figure 6).3 IRB 2400L Endurance load (In operation) Force xy Force z.com The document is for study only. load (Emergency stop) ± 2100 N 4100 ± 1400 N .we will delete . For optimal performance the frequency of the foundation with the robot weight must be higher than 30 Hz.5.com EMail:[email protected] Installation Installation and Commissioning 2. 6 Amount of space required The amount of working space required (same for both floor and inverted mounted) to operate the manipulator and controller is illustrated in Figure 7.180°. Figure 8 and Figure 9.com The document is for study only. The working range for axis 1 is +/.com EMail:[email protected] and Commissioning On-Site Installation X Z Figure 6 The directions of the stress forces.if tort to your rights. NB: There are no software or mechanical limits for the working space under the base level of the manipulator.please inform us.we will delete 13 . 2. Product Manual IRB 2400 www. 6.if tort to your rights. 14 Product Manual IRB 2400 www.com The document is for study only.please inform us.cadfamily.1 Manipulator 3421 1702 2885 560 1189 1810 Figure 7 The amount of working space required for IRB 2400L.com EMail:[email protected] Installation Installation and Commissioning 2.we will delete . please inform us.cadfamily.com EMail:[email protected] will delete 15 . Product Manual IRB 2400 www.com The document is for study only. /16.Installation and Commissioning On-Site Installation 2900 274 1441 2458 393 1002 1550 Figure 8 The amount of working space required for IRB 2400/10.if tort to your rights. please inform us.com EMail:[email protected] Installation Installation and Commissioning 2.we will delete .6.2 Controller 50 540 800 Cabinet extension Option 115 800 Extended cover Option 114 250 500 200 950 980 * Lifting points for forklift * Castor wheels 500 Figure 9 The amount of space required for the controller.cadfamily. 16 Product Manual IRB 2400 www.if tort to your rights.com The document is for study only. com EMail:cadserv21@hotmail. When the controller or the voltage device is connected as illustrated above.please inform us. The push-buttons are marked with the appropriate axis name. In they are mixed up.cadfamily. Product Manual IRB 2400 www. +24 V B8 0 V C10 Burndy contact: R1. an external voltage supply (24 V DC) must be connected to enable engagement of the brakes.com The document is for study only. 0V + 24 V DC 8 11 14 Figure 10 Connection of external voltage to enable engagement of the brakes. damage can be caused to a resistor and the system board. The names of the axes and their motion patterns are shown in Figure 11. option 640 is chosen (see Figure 10).MP4-6 1 4 7 10 13 2 5 3 6 91 12 15 NOTE! Be careful not to interchange the 24 V.Installation and Commissioning On-Site Installation 2. the brakes can be engaged separately using the push-buttons on the connection plate at the rear of the base. The voltage supply should be connected to the contact at the base of the manipulator or to the Burndy contact in the base under the cover if. Incorrectly connected power can release all brakes.and 0 V pins. External power must be connected according to Figure 10.if tort to your rights. causing simultaneously movement of all axes.7 Manually engaging the brakes All axes are equipped with holding brakes. If the positions of the manipulator axes are to be changed without connecting the controller.we will delete 17 . com The document is for study only.we will delete . make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects. its working space should be limited mechanically for axes 2 and 3 with extra stop lugs and axis 3 with limit switches.please inform us. The axes become activated very quickly and may cause damage or injury. Installation of extra stops for the main axes 1 and 2 and installation of switches on axis 3 is described below.cadfamily. 2. Special kits for limitation of the working space can be ordered.if tort to your rights.com EMail:[email protected] Installation Installation and Commissioning WARNING: Be very careful when engaging the brakes. and also by using software. 18 Product Manual IRB 2400 www. Axis 4 Axis 5 Axis 6 Axis 3 Axis 2 Axis 1 Figure 11 The robot axes and motion patterns. Limiting the working space using software is described in the System Parameters in the User’s Guide.8 Restricting the working space When installing the manipulator. 8.cadfamily.we will delete 19 .1 Axis 1 The range of rotation for axis 1 can be limited mechanically by fitting extra stop lugs to the base (Figure 12).Installation and Commissioning On-Site Installation 2. see Figure 13. 3HAB 7310-1 9ADA 312-9 9ADA 183-65 Name Stop axis 1.com EMail:cadserv21@hotmail. Product Manual IRB 2400 www.8 Figure 12 Location of extra stop lugs.5 M12x30 8.com The document is for study only. CAUTION! The original stop pin must not be removed under any circumstances. Item 1 2 3 Qty 2 4 4 Article No.please inform us. When drilling holes for extra stop lugs. removable Plain washer Hex socket head cap screw Dimension 13x24x2.if tort to your rights. working range Min. cut threads. 20 Product Manual IRB 2400 www. M12. Note 2 Note 1 Note 1 Max. working range Drilling not allowed inside this sector Center lines for the hidden stiffening ribs Figure 13 Where to drill the holes for the extra stop lugs.we will delete . Tighten the screws.com EMail:[email protected] tort to your rights.please inform us.2. Mount the stops without thightening the screws. 10. Turn axis 1 manually and check the working range between the stops. Drill the holes through.com The document is for study only. If necessary correct the angle of impact.On-Site Installation Installation and Commissioning NOTE 1 Only this mounting direction. NOTE 2 Make a copy and cut out the drilling pattern (Figure 14) and use it to mark out the location of the two holes on each stop.cadfamily. com EMail:[email protected] (x2) 50 20 32 60 Figure 14 Drilling pattern. Product Manual IRB 2400 www.Installation and Commissioning On-Site Installation R 264 mm ∅ 10.we will delete 149 Scale 1:1 21 .please inform us.cadfamily.if tort to your rights.com The document is for study only. 22 Product Manual IRB 2400 www.if tort to your rights. see Figure 15.8. Figure 15 Mechanically limiting axis 2.please inform us.com The document is for study only.com EMail:[email protected] Axis 2 The range of rotation for axis 2 can be limited mechanically by fitting extra stop lugs on the lower arm.On-Site Installation Installation and Commissioning 2.we will delete . please inform us.cadfamily.if tort to your rights.com The document is for study only.Installation and Commissioning On-Site Installation Number of parts needed for different angles are shown in the table below: Item number.com EMail:[email protected] will delete 23 . see Figure 15 1 Working range +110o / -100o +110o / -70o +110o / -40o +80o / -100o +80o / -70o +80o / -40o +50o / -100o +50o / -70o +50o / -40o +20o / -100o +20o / -70o +20o / -40o 1 2 1 2 3 2 3 4 3 4 5 2 Qty 2 2 2 2 2 2 2 2 2 2 2 2 4 2 4 6 4 6 8 6 8 10 3 Product Manual IRB 2400 www. com The document is for study only.we will delete .cadfamily. Figure 16 Mounting of electrical stop axis 3. which senses the position via a cam.On-Site Installation Installation and Commissioning 2.please inform us.8.3 Axis 3 The working range of axis 3 can be limited by fitting an electric switch on the gear box axis 3. see Figure 16.if tort to your rights.com EMail:cadserv21@hotmail. 24 Product Manual IRB 2400 www. we will delete 25 . option 04y. /16. Product Manual IRB 2400 www.com The document is for study only. The function “Resetting the work area for an axis”. or if the robot is jogged uncalibrated. Follow the procedure below to dismantle the mechanical stop.if tort to your rights. the mechanical stop on axis 4 should be removed.com EMail:[email protected] and Commissioning On-Site Installation 2.g. included in Advanced motions 3. 3 Remove the damper. If the robot is provided with cabling on the upper arm. Note that when the damper is removed. 2 Slowly rotate axis 4 until the damper <30> is visible through the hole.B. 1 Loosen the four screws <32> and dismantle the cover.0. 4 Remount the cover and tighten the screws with 15 Nm. e.cadfamily. To enable useage of this function. axis 4 does not have a mechanical stop. Only valid for IRB 2400/10. can also be used for axis 4. See also Foldout 7 in Spare Parts List. the cabling can be damaged when the function “Resetting the work area for an axis” is used.9 Unlimited working range axis 4 N.please inform us. 26 Product Manual IRB 2400 www.if tort to your rights.we will delete 135 .cadfamily. IRB 2400/10 and IRB 2400/16 85 110 463 65 177 70 25 M6 (2x) Depth of tread 14 M8 (3x) IRB 2400L 70 65 35 37 M5 (2x) Depth 6 M8 (2x) Depth 14 135 150 Figure 17 Holes for extra equipment.10 Mounting holes for equipment on the manipulator NB: Never drill a hole in the manipulator without first consulting ABB Flexible Automation.please inform us.com The document is for study only.com EMail:[email protected] Installation Installation and Commissioning 2. IRB 2400 (Dimensions in mm). we will delete 27 .please inform us.com EMail:[email protected] and Commissioning On-Site Installation M8 (3x) depth 16 R = 77 M8 (3x) depth 16 R = 92 120o 120o 120o 120o 38o 38o IRB 2400/10 and IRB 2400/16 M5 (2x) 22 78 43 90 IRB 2400L 82 Figure 18 Holes for extra equipment.com The document is for study only. this option occupies the holes on the gearbox axis 3 side.if tort to your rights. IRB 2400 (Dimensions in mm) If the option 623 is mounted. Product Manual IRB 2400 www. 11 Loads Regarding load diagram.cadfamily.027 D=25 -0 B A 90o (4x) 6 A-A Figure 19 The mechanical interface of IRB 2400L (mounting flange). see chapter 3.012 H7 0.if tort to your rights.we will delete D=63 +0 -0.039 h8 . permitted extra loads (equipment) and location of extra loads (equipment). The loads must also be defined in the soft ware. A o D=6 -0 30 5x +0.On-Site Installation Installation and Commissioning .05 9 H8 B M6 (4x) R=20 +0.05 B The hole can go through 8 M6 (6x) 60 o R=25 D=31.com The document is for study only. 2.046 h8 D=50 +0 -0. 28 Product Manual IRB 2400 www.012 -0 H7 B ∅ 0.5 +0.039H8 -0 A 7 A-A Figure 20 The mechanical interface of IRB 2400/10 and IRB 2400/16 (mounting flange).com EMail:[email protected] inform us.4 in Product Specification IRB 2400 (Technical specification). A 45 o D=6 +0. see User´s Guide. Installation and Commissioning 2. See Product Specification. speed for a load mounted on the IRB 2400 is 7 m/s.if tort to your rights.12 Connecting the controller to the manipulator On-Site Installation Two cables are used to connect the controller to the manipulator. section 3. Applicable standards are ISO/DIS 11161 (see also chapter 3. The fence must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. 2.we will delete 29 .13) and prEN 999:1995. 2.8. velocities of the robot axes and from the position at which the robot is working in the workcell. The connection on the manipulator is located on the rear of the robot base. Motor cable.cadfamily. A screwed connection is designated XT.12. The maximum speed is determined from the max. XP1 XS1 XS2 Measurement cable. XP2 Figure 21 Connections on the cabinet wall.com EMail:[email protected] inform us.com The document is for study only. The max. A connector is designated XP when it has pins (male) and XS when it has sockets (female).1 Connection on left-hand side of cabinet The cables are connected to the left side of the cabinet using an industrial connector and a Burndy connector (see Figure 21). Product Manual IRB 2400 www.13 Dimensioning the safety fence A safety fence must be fitted around the robot to ensure a safe robot installation. one for measuring signals and the other for motor and brakes. The cable connector is supplied but not the cable.3-2. Connect phase 1 to L1 (N.com The document is for study only. make sure that the other end of the cable is disconnected from the line voltage. or to a optional socket on the left-hand side of the cabinet or the lower section of the front. Not dependent on phase sequence) 2 to L2 3 to L3 0 to XT26. Circuit Diagram. 30 Product Manual IRB 2400 www. conductor size is 6 mm2 (AWG 10). Pull the mains cable through the gland (see Figure 22).14. 5. Fasten the cover plate.14 Mains power connection Before starting to connect the mains. Release the connector from the knob by depressing the red button located on the upper side of the connector (see Figure 22).com EMail:[email protected](zero is needed only for option 432) and protective earth to NOTE! Max.On-Site Installation Installation and Commissioning 2.if tort to your rights. 2.we will delete . 2. Snap the breaker on to the knob again and check that it is fixed properly in the right position. Retighten after approx. 3. Tighten the cable gland. see rating plate on the controller.1 Connection to the mains switch A gland for the mains cable is located on the left cabinet wall. Connect as below (also see chapter 11.5 Nm. 1 week.B. PE Cable gland Connector Figure 22 Mains connection inside the cabinet.cadfamily.): 1. The power supply can be connected either inside the cabinet.please inform us. The mains supply cables and fuses should be dimensioned in accordance with rated power and line voltage. 4. Tighten torque 2. 7-8 X3. X2.10-12 X3. B7-B8 A9-A10.Installation and Commissioning 2. X2.7-9 X1.com EMail:cadserv21@hotmail. The teach pendant and peripheral equippment are properly connected.com The document is for study only. External customer connections. B9-10 A15-A16.cadfamily. The controller mains section is protected with fuses. 5. 4. X4.5-6.10. X4. B15-16 Panel unit X1. X2.3-4. The operating mode selector on the operator’s panel is in Manual mode position.7-8.5-6 For more information.9-10. The robot has been properly mechanically mounted and is stable 2. Cable connectors are supplied (option 133 .14. 2. When external safety devices are used check that these have been connected or that the following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw terminals on the panel unit) are strapped: External limit switches External emergency stop External emergency stop.7-8.9. Product Manual IRB 2400 www.7-8 X3. B5-B6 A3-A4. X4. The electrical connections are correct and corresponds to the identification plate on the controller. CEE connector DIN connector Figure 23 Mains connection via an optional wall socket. check that the following have been performed: 1. 6. 3. X2.10-12.if tort to your rights.15 Inspection before start-up Before switching on the power supply.please inform us. The physical environment is as specified. B1-B2 A11-A12.we will delete 31 .3-4 X1. or via an industrial Harting connector (DIN 41 640). 7.7-9.9-10 X1. See Figure 23.11-12. B13-B14 A7-A8. That limiting devices that establish the restricted space (when utilized) are installed. X4. B3-B4 A1-A2.134). internal 24 V General stop + General stop Auto stop + Auto stop Motor off clamping XS3 A5-A6. see Chapter 3.11-12 X3. B11-B12 A13-A14.2 Connection via a power socket On-Site Installation You can also connect the mains supply via an optional wall socket of type CEE 3x16 and 3x32 A. Connection of safety chains and Chapter 3. com EMail:cadserv21@hotmail. 5. 3.1 General 1.16. press the enabling device on the teach pendant. Update the revolution counters according to 2.if tort to your rights. Otherwise continue as follows (no software installed): . 2.2. The air hose is sensitive to wear because it is part of the moving cable harness. . verify that 32 Product Manual IRB 2400 www.please inform us. The risk of failure is greater in this case compared with a hose that is stationary and clamped. Batteries Connect the batteries to the connectors X3 and X4.16 Start-up 2. in order to fully charge the batteries for the serial measurement board. proceed to pos. situated below the batteries. 3 below.Install the software as described in Chapter 4. Installing the Control Program. 7.16.16.com The document is for study only.cadfamily.On-Site Installation Installation and Commissioning N. A welcome message is shown on the teach pendant display. 4. To switch from MOTORS OFF to MOTORS ON. Figure 24 Location of batteries. 2. Switch on the mains switch on the cabinet. Check the calibration position according to section 2.Connect the batteries for memory backup (see Figure 24). After having checked the above.3. 6. This test takes approximately 1 minute. view from above. When the controller with the manipulator electrically connected are powered up for the first time. If the robot is supplied with software already installed.B. ensure that the power supply is connected for at least 36 hours continuously. The robot performs its self-test on both the hardware and software.we will delete . 10. .in automatic (normal) operation. stop and mode selection (including the key lock switches) control devices function as intended.when the battery (on the manipulator) is discharged (it takes 36 hours with the mains switch on to recharge the battery).cadfamily. the revolution counter settings are stored using the teach pendant.we will delete 33 . the robot operates properly and has the capability to handle the product or workpiece.com EMail:cadserv21@hotmail. . When such a message appears. the revolution counter of the manipulator must be updated using the calibration marks on the manipulator (see Figure 29).the safeguarding is in place. 16.The robot is now ready for operation.when there has been a resolver error. the start. 9. 2. .if tort to your rights. emergency stop and safety stop (where included) circuits and devices are functional.when the signal between the resolver and the measuring panel unit has been interrupted. and 15.16.in reduced speed. the robot operates properly and has the capability to perform the intended task at the rated speed and load. Press the enabling device on the teach pendant and.the teach and playback facilities function correctly.Installation and Commissioning On-Site Installation 8. 13.please inform us. a message will be displayed on the teach pendant telling you that the revolution counters are not updated. 14. WARNING: Working inside the robot working range is dangerous.2 Updating the revolution counter When pressing the enabling device on a new robot. each axis moves and is restricted as intended.com The document is for study only. 11. using the joystick. as follows: Product Manual IRB 2400 www. When all axes have been positioned as above. 12. manually move the robot so that the calibration marks lie within the tolerance zone (see Figure 29). Examples of when the revolution counter must be updated: .when one of the manipulator axes has been manually moved with the controller disconnected. it is possible to disconnect and isolate the external power sources. we will delete . window key (see Figure 25). File Edit View Calib Service Calibration Unit IRB Status 1(1) Not rev. 2. The window in Figure 26 appears. choose View: Calibration. these will be listed in the window.com EMail:cadserv21@hotmail. 3. window key from which the Service window can be chosen. Select Service in the dialog box shown on the display. Press the Misc. 34 Product Manual IRB 2400 www.cadfamily. 7 4 1 1 2 8 5 2 0 9 6 3 P1 P2 P3 Figure 25 The Misc.com The document is for study only. If there are several units connected to the robot.please inform us. counter update Figure 26 This window shows the status of the revolution counters. Press Enter . Then. 4.if tort to your rights.On-Site Installation Installation and Commissioning 1. 10. Confirm by pressing OK.if tort to your rights. Press the function key All to select all axes if all axes are to be updated. Thus. it will cause incorrect positioning. Rev. Counter Incl All Cancel OK Figure 27 The dialog box used to select axes whose revolution counters are to be updated. include axes and press OK.com The document is for study only.com EMail:cadserv21@hotmail. Choose Calib: Rev. Counter X X Rev.cadfamily. check the calibration very carefully after each update. 7.we will delete 35 . Start the update by pressing OK. Product Manual IRB 2400 www. Select the desired unit in the window. Otherwise. Counter Update! IRB To calibrate. Check the calibration as described in Chapter 2.Installation and Commissioning On-Site Installation 5.3.Save systemparameters on a floppy disk. A window like the one in Figure 28 appears. Counter Rev. The window in Figure 27 appears. Counter Update! IRB The Rev. Counter for all marked axes will be update. Rev.16. OK to continue? Cancel OK Figure 28 The dialog box used to start updating the revolution counter. 8. If a revolution counter is incorrectly updated. Incorrect updating can damage the robot system or injure someone. as in Figure 26. Checking the calibration position. select the desired axis and press the function key Incl (the selected axis is marked with an x). 9. It cannot be undone. 6. Axis X X 1 2 3 4 5 6 Not updated Not updated Calibrated Calibrated Not updated Not updated Status 1(6) Rev. Counter Update. Counter Rev.please inform us. please inform us. axis 1.On-Site Installation Installation and Commissioning IRB 2400/ 10/ 16 Punch.if tort to your rights. 3HAB 8223-1 2 markings 36 Product Manual IRB 2400 www. axis 1. 3HAB 8184-1 Punch. 3HAB 8184-1 Punch. axis 3. 3HAB 8223-1 Punch. axis 6. axis 1. 3HAB 8223-1 2 markings IRB 2400L Punch. axis 4. 3HAB 8223-1 Punch. axis 1. 3HAB 8223-1 Punch.com The document is for study only. axis 1.we will delete . 3HAB 8223-1 Punch. axis 2. 3HAB 8223-1 Punch.cadfamily. axis 1. Punch. 3HAB 8223-1 Figure 29 Calibration marks on the manipulator.com EMail:cadserv21@hotmail. make sure that the robot cannot collide with any other objects in the working space. 2.please inform us.16.4 Alternative calibration positions See chapter 12. Product Manual IRB 2400 www.cadfamily. follow intructions displayed on the teach pendant.com EMail:cadserv21@hotmail. the setting of the revolution counters must be repeated. see Figure 29. When the robot stops. Check that the calibration marks for each axis are at the same level. If they are not. Before start-up. If they are not.16. Using the diskette. see Figure 29. Repairs.Installation and Commissioning On-Site Installation 2.if tort to your rights.we will delete 37 . Using the Jogging window on the teach pendant: Open the Jogging window and choose running axis-by-axis.5 Operating the robot Starting and operating the robot is described in the User’s Guide. Check that the calibration marks for each axis are at the same level.16. the setting of the revolution counters must be repeated. switch to MOTORS OFF. Using the joystick. move the robot so that the read-out of the positions is equal to zero.com The document is for study only. 2. Controller Parameters: Run the program \ SERVICE \ CALIBRAT \ CAL 2400 on the diskette.3 Checking the calibration position There are two ways to check the calibration position and they are described below. com EMail:[email protected] will delete .please inform us.cadfamily.if tort to your rights.On-Site Installation Installation and Commissioning 38 Product Manual IRB 2400 www.com The document is for study only. The cable is screened and has four conductors. Measuring signals – Shielded cable with twisted pair conductors. Allen-Bradley Remote I/O.g. Control signals – digital operating and data signals (digital I/O.Installation and Commissioning Connecting Signals 3 Connecting Signals 3. CAN bus with DeviceNet for distributing I/O units. the following rules apply to the cables of certain signal classes: Power signals -Shielded cable with an area of at least 0.please inform us. Data communication signals – field bus connection.2 Selecting cables All cables laid in the controller must be capable of withstanding 70o C. e. Control signals – Shielded cable.). ABB article no. Product Manual IRB 2400 www. Cables according to Allen-Bradley specification. Note that a separate cable for supply of I/O load is required.we will delete 39 . Thin cable according to DeviceNet specification release 1. Interbus-S: Cables according to Phönix specification. 3HAB 8277-1. Data communication signals – Shielded cable with twisted pair conductors. should be used for connections between the DSQC 351 and external Interbus-S bus. e.g. Measuring signals – analog measuring and control signals (resolver and analog I/O). Signals from different classes must not be mixed.1 Signal classes Power – supplies external motors and brakes. safety stops. Note that any local standards and regulations concerning insulation and area must always be complied with. e.g. In addition.if tort to your rights. must be used. A specific cable should be used for field bus connections.2.com The document is for study only. 3. “Blue hose”. two for electronic supply and two for signal transmission. Different rules apply to the different classes when selecting and laying cable.75 mm2 or AWG 18.com EMail:cadserv21@hotmail. “Green type”. should be used for connections between DSQC 350 and the Allen-Bradley PLC bus. computer link.cadfamily. etc. Connecting Signals Profibus DP: Installation and Commissioning Cables according to Profibus DP specification should be used for connections between the I/O unit DSQC 352 and the external Profibus DP bus. 3. Designation X(T) XP XS Screwed terminal Male (pin) Sockets (female) 40 Product Manual IRB 2400 www. +24 V DC +0 V The diode should be dimensioned for the same current as the relay coil. The varistor should be dimensioned for the same energy as the relay coil. and other units must be clamped in a similar way.please inform us.we will delete . Figure 30 illustrates how this can be done. solenoids. 1W C 0.1 µF > 500 V max voltage 125 V nominal voltage Figure 30 Examples of clamping circuits to suppress voltage transients. Note that the turn-off time for DC relays increases after neutralisation. safety stops. external emergency stops.. Varistors give shorter turn-off times. especially if a diode is connected across the coil.cadfamily. and a voltage of twice the supply voltage.4 Connection types I/O. External relay coils. can be supplied on screwed connections or as industrial connectors. Neutralising the coils lengthens the life of the switches that control them. and a voltage of twice the supply voltage. etc.if tort to your rights. or AC voltage R C +0 V R 100 ohm. +24 V DC.1 .com The document is for study only. 3.3 Interference elimination Internal relay coils and other units that can generate interference inside the controller are neutralised.com EMail:cadserv21@hotmail. 5 mm2. see instructions from contact supplier. ensure that such conductors are not connected at the other end of the cable (antenna effect). Circuit Diagram. In each industrial connector there is space for four rows of 16 conductors with a maximum conductor area of 1.5. A maximum of two cables may be used in any one connection. In environments with much interference. A special extractor tool must be used to remove pins from industrial connectors. disconnected conductors should be grounded (0 V) at both ends. A maximum of two conductors may be pressed into any one pin. It should be noted that the screen must continue right up to the screw terminal. In environments with much interference.5 mm2.Installation and Commissioning Connecting Signals 3. The pin can then be snapped into the actual contact. press a pin or socket on to each non-insulated conductor.com EMail:cadserv21@hotmail. Bend unused conductors backwards and attach them to the cable using a clasp. for example. 3. Also. disconnected conductors should be grounded (0 V) at both ends. both of them are pressed into the same pin. The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included).please inform us. 3. ensure that such conductors are not connected at the other end of the cable (antenna effect). The installation should comply with the IP54 (NEMA 12) protective standard. In order to prevent interference. for example. The pull-relief clamp must be used when connecting the shield to the case. In order to prevent interference. When two conductors must be connected to the same pin. Push the pin into the connector until it locks.com The document is for study only.5.5 Connections Detailed information about connection locations and functions will be found in chapter 11. Bend unused conductors backwards and attach them to the cable using a clasp.2 To connectors (option) Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652) can be found on the left-hand side or front of the cabinet (depending on the customer order) See Figure 31 and Figure 22.if tort to your rights. When contact crimping industrial connectors. The cable screen must be connected to the cabinet wall using EMC.25 and 1. the following applies: Using special tongs.1 To screw terminal Panel unit and I/O units are provided with keyed screw terminals for cables with an area between 0.cadfamily. Product Manual IRB 2400 www.we will delete 41 . Measurement system cable Figure 31 Positions for connections on the left-hand side of the controller.cadfamily.com The document is for study only.if tort to your rights.Connecting Signals Installation and Commissioning Space for cable glands XS 3 (safety) Prepared for further connectors XS 5 (customer signals) XS17.com EMail:cadserv21@hotmail. Position switch XS 1.please inform us.we will delete . CAN bus connector XS 6 (customer power) XS 7 (external axes) XS 8. Motor cable XS 2. 42 Product Manual IRB 2400 www. Installation and Commissioning Connecting Signals 3.CP R2.com EMail:cadserv21@hotmail. 250 mA). there are cables and air hose integrated into the manipulator’s cabling.we will delete 43 . Inner hose diameter: 8 mm. 2 A). Product Manual IRB 2400 www.B The air hose is sensitive to wear because it is part of the moving cable harness. N. /16. one Burndy UTG 014 12SHT-connector and one Burndy UTG 018 23SHT-connector on the rear part of the upper arm.CS Air R 1/4” Figure 33 Location of customer connections. IRB 2400L. The risk of failure is greater in this case compared with a hose that is stationary and clamped. the customer connections are available at the front of the upper arm. one protective earth.CS Air R1/4” R2.CS Air R 1/4” R2.please inform us.CS Air R1/4” Figure 32 Location of customer connections.cadfamily. Max. When option 04y is chosen.com The document is for study only. IRB 2400/10. R1. Number of signals: IRB 2400/10 and /16 IRB 2400L 23 (50 V.6 Customer connections on manipulator For connection of extra equipment on the manipulator. 500 mA) R1.CP R3. Connections: R1/4” in the rear part of the upper arm and at the base.if tort to your rights. 8 bar. 12 (60 V.CP/CS Air R1/4” R3. 10 (250 V. 14-0. no 3HAA 2613-3 2152 0363-5 See Pin and See socket table below 3HAA 2602-3 5217 649-34 See Pin and Socket table below 3HAA 2601-3 5217 1038-5 5217 649-36 3HAA 2614-3 5217 1032-5 UTG 18 ADT UTG 18 AD UTG 18 PG Burndy EMC Burndy Burndy Bottled shaped Angled UTO 618 23 PN04 UTO 618 23 PN Burndy EMC Burndy Type UTO 018 23 SHT UTFD 16 B Comments Burndy Burndy 4 5 Pin connector 23p Pin 6 7 8 Adaptor Cable clamp Shrinking hose Shrinking hose 44 Product Manual IRB 2400 www. E155 DIN 43 652 DIN 43 652 DIN 43 652 PFLITSCH 0. (Regarding Item No see Figure 34) Item No 1 2 3 4 5 6 Name Female insert 40p Hood Compression gland Socket Sockets Key pin ABB art. (Regarding Item No see Figure 35) Item No 1 2 3 Name Socket con.CP/CS Signals on the manipulator base.5 mm2 Comments IRB 2400/10.Connecting Signals Installation and Commissioning To connect to power and signal conductors from the connection unit to the manipulator base and on the upper arm.CS/R3.please inform us.5 mm2 0. /16 Connector R2. no 3HAB 7284-1 3HAB 7285-1 3HAB 7283-1 5217 1021-4 5217 1021-5 5217 687-9 Type DIN 43 652 DIN 43 652 DS/55 ZU. 23p Gasket Socket ABB art.cadfamily.CS Signals on the upper arm.we will delete . /16 Connector R1.com EMail:cadserv21@hotmail. the following parts are recommended: IRB 2400/10.if tort to your rights.com The document is for study only.5-1. DN 155D. (Regarding Pos see Figure 35) Pos 1 2 3 4 5 6 7 8 Name Socket connector Gasket Socket Pin connector 12p Pin Adaptor Cable clamp Shrinking hose Shrinking hose ABB art. no 3HAA 2613-2 5217 649-64 See socket table below 3HAA 2602-2 5217 649-7 See pin table below 3HAA 2601-2 5217 1038-3 5217 649-8 3HAA 2614-2 5217 1032-4 Type Connecting Signals Comments Burndy Burndy UTO 014 12 SHT UTFD 13 B UTO 614 12 PN04 UTO 614 12 PN Burndy EMC Burndy UTG 14 ADT UTG 14 AD UTG 14 PG Burndy EMC Burndy Burndy Bottled shaped Angled IRB 2400L Connector R2. no 3HAA 2613-2 5217 649-64 See below 3HAA 2602-2 5217 649-7 See below 3HAA 2601-2 5217 1038-3 5217 649-8 3HAA 2614-2 5217 1032-4 URG 14 ADT UTG 14 AD UTG 14 PG Burndy EMC Burndy Burndy Bottled shaped Angled UTO 61412PN04 UTO 61412PN Burndy EMC Burndy Type UTO 014 12 SHT UTFD 13B Comments Burndy Burndy Product Manual IRB 2400 www.CP./R3.if tort to your rights.cadfamily. /16 Connector R2. (Regarding Item No see Figure 35) Item No 1 2 3 4 5 6 7 8 Name Socket con.please inform us.CS.we will delete 45 .com EMail:cadserv21@hotmail. 12p Gasket Socket Pin connector 12p Pin Adaptor Cable clamp Shrinking hose Shrinking hose ABB art. Power on the upper arm. on upper arm. Signals.Installation and Commissioning IRB 2400/10.com The document is for study only.CP. com The document is for study only.cadfamily.5mm2 AWG 20-26 Tin bronze (CuSu) 0.we will delete .5mm2 AWG 16-20 Socket 46 Product Manual IRB 2400 www.com EMail:cadserv21@hotmail. no 3HAA 2599-2 5217 649-64 See below 3HAA 2600-2 See below 3HAA 2601-2 5217 1038-3 5217 649-8 3HAA 2614-2 5217 1032-4 URG 14 ADT UTG 14 AD UTG 14 PG Burndy EMC Burndy Burndy Bottled shaped Angled UTO 61412 S Burndy EMC Type UTG 014 12 P UTFD 14 B Comments Burndy Burndy Name Pin ABB art. 12p Sockets Adaptor Cable clamp Shrinking hose Shrinking hose ABB art.5 .14 . no 5217 649-72 5217 649-25 5217 649-70 5217 649-3 5217 649-68 5217 649-10 5217 649-31 5217 649-73 5217 649-26 5217 649-71 5217 649-69 5217 1021-4 5217 1021-5 Type 24/26 24/26 20/22 20/22 16/20 24/26 16/20 24/26 24/26 20/22 16/18 DIN 43 652 DIN 43 652 Comments Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Ground Burndy Ground Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Machine tooling Tin bronze (CuSu) 0.please inform us.1.0.if tort to your rights. see Figure 35) Pos 1 2 3 4 5 6 7 8 Name Pin connector 12p Gasket Pin Socket con. on the manipulator base. (Regarding Pos. Signals.Connecting Signals IRB 2400L Installation and Commissioning Connector R1CS. Customer side 4. Product Manual IRB 2400 www.com The document is for study only.we will delete 47 .cadfamily.com EMail:cadserv21@hotmail. 5 Manipulator side 1.if tort to your rights.Installation and Commissioning Connecting Signals 3 2 6 1 4 5 Figure 34 Customer connector. 3 8 6 2 7 Figure 35 Burndy connector.please inform us. com EMail:[email protected] X1 . X2 X1. external safety circuits. SIO 2 CAN1 (internal unit) CAN 2 (manipulator. See also circuit diagram.we will delete . for more details. Signal identification Safeguarded stop Digital I/O Combi I/O Relay I/O RIO I/O SIO 1.cadfamily. “View of control cabinet”. external supply to electronics.4 safety signals X5 X8 X6 CONTROL PANEL XT5.Connecting Signals Installation and Commissioning 3.X4 X1. X6 X1 . customer signals XT6.com The document is for study only. X1 (SIO1) X2 (SIO2) I/O units (x4) X10 (CAN3) X16 (CAN2) Backplane Panel unit WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN MS NS ES1 ES2 GS1 GS2 AS1 AS2 X1 . position switch X9 (CAN1) XT21 (115/230 V AC supply) XT31 (24V supply) Figure 36 Screw terminal locations.please inform us. customer sockets on the robot. 48 Product Manual IRB 2400 www.if tort to your rights.X4.7 Connection to screw terminal Sockets with screwed connections for customer I/O. X2 X9 X16 X10 XT31 XT21 Location of socket terminals are shown below. customer power XT8.X4 X1 . I/O units) CAN 3 (external I/O units) 24 V supply (2 A fuse) 115/230 V AC supply Location Panel unit I/O unit I/O unit I/O unit I/O unit Backplane Panel unit Backplane Backplane Terminals X1 . two identical chains of switches must be closed. teach pendant unit GS = General mode safeguarded space Stop ES = Emergency Stop Figure 37 MOTORS ON /MOTORS OFF circuit. the robot will remain in MOTORS OFF mode. AS. LS Solid state switches Contactor ES 2nd chain interlock Drive unit GS TPU En & EN RUN Computer commands M AS Auto Operating mode selector Manual LS = Limit switch AS = Automatic mode safeguarded space Stop TPU En= Enabling device. Product Manual IRB 2400 www.com The document is for study only.we will delete 49 .Installation and Commissioning Connecting Signals 3. Figure 37 shows an outline principal diagram of the available customer connections.if tort to your rights. If any switch is open.8 The MOTORS ON / MOTORS OFF circuit To set the robot to MOTORS ON mode. GS and ES.cadfamily.com EMail:cadserv21@hotmail. As long as the two chains are not identical. the robot will switch to MOTORS OFF mode.please inform us. 11 is connected to 24 V and X3/X4:8. V drop GS/AS load at 24V GS/AS closed “1” GS/AS open “0” External supply of GS/AS Max. GS1 TPU En1 AS1 Auto1 External contactors X2:5 6 CONT1 X1:5 6 CONT2 K2 24V Man1 ES1 8 11 9 & EN RUN Interlocking K1 K2 0V 24 V 0V Ext LIM2 X2:4 3 see 3. + 9 X3:7 * X4:7 0V GS2 TPU En2 ES2 Drive unit 8 11 & Technical data per chain Limit switch: load max.1 X3:10 + Opto isol. -35VDC 300 V *) Supply from internal 24V (X3/X4:12) and 0 V (X3/ X4:7) is displayed. see section 3. X3/X4:10. +35VDC min.Connecting Signals Installation and Commissioning 3.9. potential relative to the cabinet earthing and other group of signals Signal class M Opto AS2 isol.1 X4:10 + Opto isol.com The document is for study only.if tort to your rights.9.9 Connection of safety chains 24 V * X3:12 X4:12 24 V Ext LIM1 X1:4 3 K1 0V see 3. Auto2 Man2 300 mA 1V 10 mA 4V 25 mA > 18 V <5V max. control signals Figure 38 Diagram showing the two-channel safety chain.please inform us.10. + Opto isol.cadfamily. 50 Product Manual IRB 2400 www.com EMail:[email protected] will delete . When external supply of GS and AS. V drop External contactors: load max.9 is connected to external 0 V X1-X4 connection tables. 9.8 respectively 40 mA 300 V control signals X2:2 ES2 out X2:1 External supply of ES relays = Rated current per chain Max.com The document is for study only. 24V and X1/X2:8 is connected to ext.Installation and Commissioning 3. X1/X2:9 is connected to ext.please inform us.com EMail:[email protected]. potential relative to the cabinet earthing and other groups of signals Signal class Figure 39 Terminals for emergency circuits. Product Manual IRB 2400 www. External 0V 24V Internal 0V 24V External X2:10 X2:9 X1:2 ES1 out X1:1 TPU Cabinet E-stop relay X2:7 X2:8 Chain 2 Technical data ES1 and 2 out max.if tort to your rights.we will delete 51 . When external supply. current 120 VAC or 48 VDC 120 VAC: 4 A 48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A min 22 V between terminals X1:9. voltage ES1 and 2 out max.8 and X2:9.1 Connection of ES1/ES2 on panel unit External 24V 0V Internal 24V 0V X1:10 Connecting Signals External X1:9 TPU Cabinet E-stop relay X1:7 X1:8 Chain 1 Supply from internal 24V (X1/X2:10) and 0V (X1/ X2:7) is displayed. 0V (dotted lines). potential relative to the cabinet earthing and other groups of signals Signal class Figure 42 Terminal for customer use.please inform us. 48V DC 4A 300V K1 (Motor On/Off 1) control 3.Connecting Signals Installation and Commissioning 3.com The document is for study only.3 Connection to operating mode selector X3:3 Auto1 4 5 Technical data Max. voltage Max. potential relative to the cabinet earthing and other groups of signals Signal class Figure 40 Terminals for customer use. 48V DC 4A 300V K3 (Brake) control 52 Product Manual IRB 2400 www.we will delete .4 Connection to brake contactor Technical data Max.9.com EMail:[email protected] tort to your rights. voltage Max.2 Connection to Motor On/Off contactors Technical data K2 (Motor On/Off 2) Max.9. voltage Max. current X3:2 1 X4:2 1 Max. current Max.9.cadfamily. 3. potential relative to the cabinet earthing and other groups of signals Signal class 48V DC 4A 300V MAN1 100% 6 X4:3 Auto2 4 5 control MAN2 100% 6 Figure 41 Terminals customer use. current X1:12 11 Max. com EMail:cadserv21@hotmail. LIM1:B Ext.cadfamily.X4. located on the panel unit.if tort to your rights. BRAKE A Pin 1 2 3 4 5 6 7 8 9 10 11 12 Comment Emergency stop out chain 1 Emergency stop out chain 1 External limit switch chain 1 External limit switch chain 1 0V external contactor 1 External contactor 1 Internal supply 0V of emergency stop chain 1 External supply 0V of emergency stop chain 1 External emergency stop in chain 1 External emergency stop out chain 1 Contactor for external brake Contactor for external brake Product Manual IRB 2400 www. ES1 IN Ext. WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN MS NS ES1 ES2 GS1 GS2 AS1 AS2 Chain status LED´s X1 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 X3 X2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 X4 = jumper Customer connections: X1 .please inform us. The signal names refer to the circuit diagram in chapter 11. on panel unit: X1. LIM1:A 0V CONT1 Int. 0V ES1 Ext. 0V ES1 Ext. X1 Signal name ES1 out:B ES1 out:A Ext.10 External customer connections Customer contacts.X4. ES1 OUT Ext.com The document is for study only.Installation and Commissioning Connecting Signals 3.we will delete 53 . BRAKE B Ext. man 1 Ext.if tort to your rights.please inform us. LIM2:A 24V panel CONT2 Int.cadfamily. ES2 IN Ext.com EMail:cadserv21@hotmail. com 1 Ext. MON 1:A Ext. 24V ES2 Ext.com The document is for study only. MON 1:B Ext. LIM2:B Ext. ES2 OUT Pin 1 2 3 4 5 6 7 8 9 10 11 12 Comment Emergency stop out chain 2 Emergency stop out chain 2 External limit switch chain 2 External limit switch chain 2 24V external contactor 2 External contactor 2 Internal supply 24V of emergency stop chain 2 External supply 24V of emergency stop chain 2 External emergency stop in chain 2 External emergency stop out chain 2 Not used Not used X3 Signal name Ext. 24V ES2 Ext.we will delete . man FS 1 0V GS1AS1GS1+ AS1+ 24V panel Pin 1 2 3 4 5 6 7 8 9 10 11 12 Comment Motor contactor 1 Motor contactor 1 Common 1 Auto 1 Manual 1 Manual full speed 1 0V to auto stop and general stop General stop minus chain 1 Auto stop minus chain 1 General stop plus chain 1 Auto stop plus chain 1 24V to auto stop and general stop 54 Product Manual IRB 2400 www.Connecting Signals Installation and Commissioning X2 Signal name ES2 out:B ES2 out:A Ext. auto 1 Ext. we will delete 55 . MON 2:A Ext. auto 2 Ext.if tort to your rights.cadfamily.com The document is for study only.please inform us. man FS 2 0V GS2AS2GS2+ AS2+ 24V panel Pin 1 2 3 4 5 6 7 8 9 10 11 12 Comment Motor contactor 2 Motor contactor 2 Common 2 Auto 2 Manual 2 Manual full speed 2 0V to auto stop and general stop General stop minus chain 2 Auto stop minus chain 2 General stop plus chain 2 Auto stop plus chain 2 24V to auto stop and general stop Product Manual IRB 2400 www. com 2 Ext. man 2 Ext.com EMail:[email protected] and Commissioning Connecting Signals X4 Signal name Ext. MON 2:B Ext. 11 External safety relay Installation and Commissioning The Motor On/Off mode in the controller can operate with external equipment if external relays are used.please inform us.com The document is for study only.Connecting Signals 3.cadfamily. Two examples are shown below.com EMail:cadserv21@hotmail. 56 Product Manual IRB 2400 www.we will delete .if tort to your rights. Panel unit Relays with positive action X2:6 CONT2 24 V X2:5 Ext MON 2 X4:2 K2 X4:1 X3:2 K1 Ext MON 1 X3:1 0 V X1:5 CONT1 X1:6 0V 24 V Robot 1 Robot 2 (only one channel displayed) External supply ES out External supply Cell ES AS GS ES out AS GS Safety relay To other equipment Safety gate Figure 43 Diagram for using external safety relays. 18 A (12 A if DSQC 374) Max. Note! To ensure MOTORS OFF status.0 . 1 second the power supply to the motors is shut off. 3. section System Parameters. If the switch is closed within the delay. such as when gates are used to protect against entry into the work cell. which makes restarting easier. This controlled motion stop takes place within the programmed path. 6 A (7.please inform us.1 Delayed safeguarded space stop All the robot’s safety stops are as default category 0 stops. the activating switch must be kept open for more than one second.Basic requirements”.13.1 24 V I/O supply The robot has a 24 V supply available for external and internal use. is passed.12. After approx.26.4 V Max. The 24 V I/O is not galvanically separated from the rest of the controller voltages.cadfamily. This uncontrolled motion stop may require special restart routines if the programmed path changes as a result of the stop. the power supply to the motors must be switched off immediately. the robot stops and will remain in MOTORS ON mode.com The document is for study only.safety of integrated manufacturing systems . category 0 and category 1. 3. 13 A (average value)(~ 0 A if DSQC 374) Product Manual IRB 2400 www.5 A if DSQC 374) Max. used to protect against entry into the work cell.13 Available voltage 3.Installation and Commissioning 3. see User’s Guide. Category 1 is to be preferred. A delayed stop gives a smooth stop. see below: The category 0 stop is to be used when.12 Safeguarded space stop signals Connecting Signals According to the safety standard ISO/DIS 11161 “Industrial automation systems . This voltage is used in the robot for supplying the drive unit fans and the manipulator brakes. Safety stops of category 1 can be obtained by activating the delayed safeguarded space stop together with AS or GS. 0.2 V Max. Technical data Voltage Ripple Permitted customer load Current limit Short-circuit current 24. Topic: Controller. The robot stops in the same way as a normal program stop with no deviation from the programmed path.if tort to your rights. if accepted for safety analysis purposes. The function is activated by setting a parameter. for safety analysis purposes.com EMail:cadserv21@hotmail. such as when a light curtain.we will delete 57 . there are two categories of safety stops. 2 115/230 V AC supply The robot has a AC supply available for external and internal use.15 A (230 V). 60 V continuous Max. Technical data: Potential difference to chassis earth: Permitted supply voltage: Max. max. The AC supply is not galvanically separated from the rest of the controller voltages.3 A (115 V) AC supply is available for customer connections at: XT.com EMail:cadserv21@hotmail. 500 VA 3.9-13 230 V (3.21.we will delete . 6.Connecting Signals Installation and Commissioning 24 V I/O available for customer connections at: XT.4 24 V (via 2 A fuse) for own fuses. This voltage is used in the robot for supplying optional service outlets. For example.21. The neutral wire in the external supply must be connected in such a way as to prevent the maximum permitted potential difference in the chassis earth being exceeded. fuse size is 2 A to ensure breaking at short circuit Note! DSQC 374 can not trip any fuses.30 V including ripple 58 Product Manual IRB 2400 www.6 . for example. • When there is a risk that major interference can be carried over into the internal 24 V supply An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I/O units or on the panel unit.cadfamily.please inform us.13.35 V including ripple panel unit 20.com The document is for study only. a neutral wire can be connected to the chassis earth of the controller.2 XT.3 A) N (connected to cabinet structure) 3.1 XT. 500 V for 1 minute I/O units 19 .21.31.15 A) 115 V (6. or some other common earthing point.1-5 XT. 0 V (connected to cabinet structure) 3.31.if tort to your rights.14 External 24 V supply An external supply must be used in the following cases: • When the internal supply is insufficient • When the emergency stop circuits must be independent of whether or not the robot has power on. Technical data Voltage Permitted customer load Fuse size 115 or 230 V Max.31.6-8 XT. C R2. voltage Max.5 XT6.C2 RI.CP.154 mm2 50 V AC / DC 250 mA <0.A3 RI. on upper arm.5 ohm.3 XT6. current <3 ohm.CP.G R2.cadfamily.A1 RI.CP/CS.7 XT6.com The document is for study only.CP/CS. /16 Air R1/4” R2.CP/CS.CP.CS R2.J R2.H R2.CP Figure 44 Customer connections on upper arm.L R2.K R2.please inform us.CP.D1 RI. current Customer Signals CS Conductor resistance Max.B1 RI.CP/CS.we will delete 59 .B3 CPJ CPK CPL CPM Product Manual IRB 2400 www.CP. 0.F R2.CP.1 Connections on upper arm.CP/CS.8 XT6.D R2.2 XT6.4 XT6.CP.15.CP/CS.D2 RI.CP/CSP Ground RI.M Customer contact on manipulator base (cable not supplied) Power supply CPA CPB CPC CPD CPE CPF Ground Key pin RI.10 R2. R2 see Figure 36 (optional) XT6.1 XT6. Signal name Customer terminal Customer contact controller.241 mm2 250 V AC 2A 3.CP/CS.CP/CS.B2 RI.B R2.CP. 0.CP.CP.6 XT6.9 XT6.A2 RI.C1 RI.A R2.if tort to your rights.com EMail:[email protected] Connection of extra equipment to the manipulator Technical data for customer connections Cutsomer Power CP Conductor resistance Max.CP/CS.CP.Installation and Commissioning Connecting Signals 3.H XT6.CP/CS. IRB 2400/10. voltage Max.E R2.CP. R R2.4 XT5.CS.CS/CP.14 XT5.D R2.Y R2.12 XT5.com EMail:[email protected] XT5.B R2.G R2.C9 R1.X R2.D6 R1.CS.D9 R1.CS/CP.A6 R1.Z R1.D10 3.CS/CP.please inform us.E R2.6 XT5.CS/CP.CS/CP.CS.CS.A7 R1.8 XT5.B10 R1.Connecting Signals Signals CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM CSN CSP CSR CSS CST CSU CSV CSW CSX CSY CSZ Installation and Commissioning XT5.CS/CP.A9 R1.CS.C10 R1.C6 R1.A R2.11 XT5.16 XT5.we will delete .M R2.V R2.CS/CP.CS.20 XT5.2 Connections on upper arm.U R2.H R2.A10 R1.CS/CP.if tort to your rights.5 XT5.CS/CP.B6 R1.CS.CS/CP.13 XT5.9 XT5. IRB 2400L R2.CS/CP.CS.CS.CS.B5 R1.T R2.2 XT5.CS/CP.17 XT5.D8 R1.CS/CP.L R2.CS.CS/CP.CS.19 XT5.CS Figure 45 Customer connections on upper arm.1 XT5.A8 R1.D5 R1.CS/CP.CS/CP.CS.23 R2.CS/CP.15.18 XT5.B8 R1.CS.K R2.CS.C R2.CS.W R2.CS/CP.J R2.com The document is for study only.CS/CP.D7 R1.221 XT5.CS.C7 R1.CS/CP.B7 R1.10 XT5.CS/CP.21 XT5.CS.C8 R1.C5 R1.N R2. 60 Product Manual IRB 2400 www.7 XT5.CS.cadfamily.P R2.S R2.B9 R1.CS/CP.F R2.CS/CP.15 XT5.CS.CS. we will delete 61 .3 Connection of signal lamp on upper arm (option) Signal lamp IRB 2400/10.L R1.Installation and Commissioning Connecting Signals Signal name Customer terminal Customer contact controller.CS.CS.CS.H R2.5 XT5.B R1.4 XT5.D R1.9 XT5.E R1. R2 see Figure 36 (optional) XT5.CS.CS.3 XT5.J R1.15.7 XT5.CS.C R2.CS.11 XT5.CS.CS.J R2.L R2.G R1.M 3. Product Manual IRB 2400 www.H1 + R3.10 XT5.M Customer contact on manipulator base (cable not supplied) Signals CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM R1.CS.CS.CS.CS.6 XT5.CS.CS.com EMail:[email protected] R2.A R1.CS.CS.if tort to your rights. on upper arm.CS. /16 R3.F R2.CS.cadfamily.CS.CS.8 XT5.B R2.CS.1 XT5.F R1.com The document is for study only.E R2.CS.12 R2.C R1.2 XT5.K R2.H2 - Signal lamp IRB 2400L Figure 46 Location of signal lamp.H R1.A R2.D R2.K R1.please inform us. Topic: I/O Signals. The controller can be one of the end points or be placed somewhere in the middle of the chain. section System Parameters. For setup parameters. Normally a distributed I/O unit is placed outside the controller.1 General Up to 20* units can be connected to the same controller but only four of these can be installed inside the controller.10.2 Sensors Sensors are connected to one optional digital unit.16. *) some ProcessWare reduces the number due to use of SIM boards.Connecting Signals Installation and Commissioning 3.please inform us. The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to the other end).16.if tort to your rights.com The document is for study only. The following sensors can be connected: Sensor type Digital one bit sensors Digital two bit sensors Signal level High Low High No signal Low Error status “1” “0” “01” “00” “10” “11” (stop program running) 62 Product Manual IRB 2400 www. see User’s Guide. chapter 3.16 Distributed I/O units 3. Technical data See Product Specification IRB 2400.cadfamily. 3.we will delete .com EMail:cadserv21@hotmail. I/O) CAN2 (manip. they must be supplied either by the 24 V I/O from the cabinet or externally by a power supply unit. 1 2 3 4 5 0V_CAN CAN_L drain CAN_H 24V_CAN Termination of last unit 120 Ω X5. its CAN bus is connected to CAN1.please inform us. 6 CAN3 (ext. X10 on the backplane of the control cabinet. Instead. NOTE! When only one of the X10/X16 is connected.Installation and Commissioning Connecting Signals 3. Product Manual IRB 2400 www. 3. X9 on the panel unit (see 3.we will delete 63 . X16 on the backplane of the control cabinet. I/O) 6 1 1 Figure 48 CAN connections on back plane.3 Connection and address keying of the CAN-bus Controller Panel unit: X9 X10 X16 CAN1 CAN3 CAN2 Back plane: I/O unit I/O unit I/O unit See Figure 48.com The document is for study only.cadfamily. the other must be terminated with 120 Ω. its CAN bus must be connected to CAN2. its CAN bus must be connected to CAN3. When the I/O unit is fitted outside the control cabinet. 24V_CAN must not be used to supply digital inputs and outputs. X9/X10/X16. 2. 1 2 3 4 5 0V_CAN CAN_L drain CAN_H 24V_CAN X5.com EMail:cadserv21@hotmail. When the I/O unit is fitted on the manipulator.7).if tort to your rights. 1 2 3 4 5 Figure 47 Example of connection of the CAN-bus 1. No termination is required when only CAN1 is used. When the I/O unit is fitted inside the control cabinet (this is standard when choosing the options on the Specification form).16. Connecting Signals DeviceNet Connector Installation and Commissioning Input and ID 12 1 Signal name V.we will delete .0V CAN_L DRAIN CAN_H V+ GND MAC ID 0 MAC ID 1 MAC ID 2 MAC ID 3 MAC ID 4 MAC ID 5 X5 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Description Supply voltage GND CAN signal low Shield CAN signal high Supply voltage 24VDC Logic GND Board ID bit 0 (LSB) Board ID bit 1 Board ID bit 2 Board ID bit 3 Board ID bit 4 Board ID bit 5 (MSB) 64 Product Manual IRB 2400 www.if tort to your rights.com The document is for study only.please inform us.com EMail:[email protected]. i.10. The connector contains address pins and can be keyed as shown in Figure 49.com EMail:cadserv21@hotmail. the address is 0 (which will cause an error since address 0 is used by the Panel unit). All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply. Technical data See Product Specification IRB 2400. Circuit diagram. see chapter 11. To obtain address 25: cut off address pins 1.cadfamily. 3.e. Topic: Controller. When all are connected to 0 V. 1 2 4 8 16 32 Figure 49 Examples of address keying. see User’s Guide.com The document is for study only. 63. section System Parameters.Installation and Commissioning ID setting Connecting Signals Each I/O unit is given a unique address (ID). 8 and 16. Product Manual IRB 2400 www.4 Digital I/O DSQC 328 (optional) The digital I/O unit has 16 inputs and outputs.we will delete 65 . When all terminals are unconnected the highest address is obtained. Further information For setup parameters. see figure. do not use address 0-9.if tort to your rights. divided up into groups of eight. To not interfer with other internal addresses.16.please inform us. chapter 3. (0V) 1 2 3 4 5 6 7 8 9 10 11 12 X5 contact address pins address key Example: To obtain address 10: cut off address pins 2 and 8. com EMail:[email protected] tort to your rights.please inform us.X4 Status LED’s 1 2 3 4 5 6 7 8 Installation and Commissioning OUT IN MS NS X2 OUT 9 10 11 12 13 14 15 16 IN X1 1 10 1 X4 1 X3 10 1 10 10 12 1 X5 CAN-connection. see 3. The supervision instruction must be written in the RAPID program.com The document is for study only.16. Signal name Out ch 9 Out ch 10 Out ch 11 Out ch 12 Out ch 13 Out ch 14 Out ch 15 Out ch 16 0V 24V 0V for out 9-16 24V for out 9-16 Pin 1 2 3 4 5 6 7 8 9 10* Signal name Out ch 1 Out ch 2 Out ch 3 Out ch 4 Out ch 5 Out ch 6 Out ch 7 Out ch 8 0V for out 1-8 24V for out 1-8 Pin 1 2 3 4 5 6 7 8 9 10* *) If supervision of the supply voltage is required. 66 Product Manual IRB 2400 www. a bridge connection can be made to an optional digital input. X2 Customer conn.we will delete . isol.3 X1 Unit function Opto.cadfamily.Connecting Signals CONNECTION TABLE Customer contacts: X1 . All groups are galvanically isolated and may be supplied from the cabinet 24 V I/O supply or from a separate supply. 24 V Signal name In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16 0V 0V for in 9-16 Not used Pin 1 2 3 4 5 6 7 8 9 10 Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 1-8 Not used Pin 1 2 3 4 5 6 7 8 9 10 NOTE! The input current is 5. see chapter 11. sensitive to pre-oscillation current.cadfamily.if tort to your rights.Installation and Commissioning Connecting Signals X3 Unit function Opto. The two analog outputs belong to a common group which is galvanically isolated from the electronics of the controller. see User’s Guide.please inform us. Product Manual IRB 2400 www. to prevent disturbances.5 AD Combi I/O DSQC 327 (optional) The combi I/O unit has 16 digital inputs divided into groups of 8.com EMail:cadserv21@hotmail. Topic: Controller. X4 Customer conn.16.10. isol.we will delete 67 . When connecting outputs. The supply to the two analog outputs is generated from 24 V_CAN (with galvanically isolated DC/AC converter). 3. Circuit diagram. Technical data See Product Specification IRB 2400. a serial resistor (100 Ω) may be used.5 mA (at 24V) on the digital inputs.com The document is for study only. A capacitor connected to ground. causes a short rush of current when setting the input. section System Parameters. chapter 3. and 16 digital outputs divided into two groups of 8. Further information For setup parameters. X2 Customer conn. see 3.X4.com The document is for study only.we will delete .16.please inform us. 68 Product Manual IRB 2400 www.if tort to your rights. isol.Connecting Signals CONNECTION TABLE Customer contacts: X1 . Signal name Out ch 9 Out ch 10 Out ch 11 Out ch 12 Out ch 13 Out ch 14 Out ch 15 Out ch 16 0V 24V 0V for out 9-16 24V for out 9-16 Pin 1 2 3 4 5 6 7 8 9 10* Signal name Out ch 1 Out ch 2 Out ch 3 Out ch 4 Out ch 5 Out ch 6 Out ch 7 Out ch 8 0V for out 1-8 24V for out 1-8 Pin 1 2 3 4 5 6 7 8 9 10* *) If supervision of the supply voltage is required.3 X1 Unit function Opto. X6 Status LED’s 1 2 3 4 5 6 7 8 Installation and Commissioning OUT IN MS NS X2 OUT 9 10 11 12 13 14 15 16 IN X1 1 10 X6 1 10 1 6 X3 X4 1 10 1 10 12 1 X5 CAN-connection.cadfamily. a bridge connection can be made to an optional digital input.com EMail:cadserv21@hotmail. The supervision instruction must be written in the RAPID program. we will delete 69 . X4 Customer conn. a serial resistor (100 Ω) may be used.cadfamily. 24 V Signal name In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16 0V 0V for in 9-16 Not used Pin 1 2 3 4 5 6 7 8 9 10 Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 1-8 Not used Pin 1 2 3 4 5 6 7 8 9 10 NOTE! The input current is 5.if tort to your rights. isol.please inform us.Installation and Commissioning Connecting Signals X3 Unit function Opto.com EMail:cadserv21@hotmail. causes a short rush of current when setting the input. When connecting outputs. A capacitor connected to ground. sensitive to pre-oscillation current.com The document is for study only. X6 Signal name AN_ICH1 AN_ICH2 0V 0VA AN_OCH1 AN_OCH2 Pin 1 2 3 4 5 6 Explanation For test purpose only For test purpose only 0V for In 1-2 0V for Out 1-2 Out ch 1 Out ch 2 Product Manual IRB 2400 www. to prevent disturbances.5 mA (at 24V) on the digital inputs. Circuit diagram. 3 for -10/+10V and 1 for 4-20mA.6 Analog I/O DSQC 355 (optional) The analog I/O unit provides following connections: 4 analog inputs.com EMail:[email protected]. Technical data See Product Specification IRB 2400.DeviceNet connectors See section 3.if tort to your rights. X 5 .please inform us.16. 4 analog outputs.3 on page 63. see User’s Guide. X3.com The document is for study only. CONNECTION TABLE Customer contacts: X1. chapter 3. which may be used for analog sensors etc. Further information For setup parameters. -10/+10V.10.Connecting Signals Installation and Commissioning 3. section System Parameters. see chapter 11.16.X8 X8-Analog inputs X7-Analog outputs Bus staus LED’s X8 S2 S3 X2 X5 X3 X7 Analog I/O DSQC 355 ABB Flexible Automation X5-DiviceNet input and ID connector Figure 50 Analog I/O unit Not to be used Connector X5. 70 Product Manual IRB 2400 www. Topic: Controller. 24V to supply external equipment wich return signals to DSQC 355.we will delete . for control of analog functions such as controlling glueing equipment etc. com The document is for study only. -10/+10V Analog output 2. 0 V Analog output 2.we will delete 71 . 0 V Analog output 3.Installation and Commissioning Connector X7 .Analog outputs X7 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Connecting Signals 12 1 24 13 Signal name ANOUT_1 ANOUT_2 ANOUT_3 ANOUT_4 Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used GND GND GND GND GND GND Description Analog output 1.com EMail:cadserv21@hotmail. 0 V Product Manual IRB 2400 www. -10/+10V Analog output 3.cadfamily. 4-20 mA Analog output 1.please inform us. -10/+10V Analog output 4. 0 V Analog output 4.if tort to your rights. cadfamily.com The document is for study only. 0V Analog input 2. 0V 72 Product Manual IRB 2400 www.we will delete . -10/+10 V +24VDC supply +24VDC supply +24VDC supply +24VDC supply +24VDC supply +24VDC supply +24VDC supply +24VDC supply Analog input 1.if tort to your rights.Analog inputs Installation and Commissioning 16 1 32 17 Signal name ANIN_1 ANIN_2 ANIN_3 ANIN_4 Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used +24V out +24V out +24V out +24V out +24V out +24V out +24V out +24V out GND GND GND GND GND GND GND GND X8 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Description Analog input 1. 0V Analog input 4. -10/+10 V Analog input 4. -10/+10 V Analog input 3.com EMail:cadserv21@hotmail. 0V Analog input 3.Connecting Signals Connector X8 . -10/+10 V Analog input 2.please inform us. we will delete DSQC 354 Encoder CAN Rx CAN Tx MS NS POWER ABB Flexible Atomation 73 .Installation and Commissioning Connecting Signals 3. see section 3. Further information User Reference Description Conveyor Tracking. Circuit diagram.com The document is for study only. Customer terminals: X20 Conveyor connection X20 Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A X5 X3 X5-DeviceNet input and ID connector X3 Not to be used Device Net connector X5.16.please inform us.7 Encoder interface unit. see User’s Guide.cadfamily. DSQC 354 Product Manual IRB 2400 www. The encoder is used for installation on a conveyor to enable robot programs to synchronize to the motion (position) of the conveyor.3 on page 63 Figure 51 Encoder unit. Topic: Controller. The digital input is used for external start signal/ conveyor synchronization point.com EMail:cadserv21@hotmail. DSQC 354 The encoder interface unit provides connections for 1 encoder and 1 digital input.if tort to your rights.16. For setup parameters. section System Parameters. see chapter 11. please inform us.com EMail:cadserv21@hotmail. As can be seen from the illustration. 74 Product Manual IRB 2400 www. and the on-board computer uses quadrature decoding (QDEC) to compute position and direction.cadfamily.if tort to your rights.com The document is for study only. The wiring diagram in Figure 52 shows how to connect the encoder and start signal switch to the encoder unit. the encoder is supplied with 24 VDC and 0V.we will delete .Connecting Signals Installation and Commissioning Encoder unit 24 V I/O or external supply 0V Encoder Synch switch 1 2 24 V DC 3 0V 4 A 5 B 6 24 V DC 7 0V 8 9 10 11 12 10-16 not to be used 13 14 15 16 Opto Opto Opto Opto Opto Opto Galvanic insulation Figure 52 Encoder connections. The encoder output 2 channels. we will delete 75 .cadfamily.please inform us.Encoder and digital input connections Connecting Signals Input and ID 1 Signal name 24 VDC 0V ENC ENC ENC_A ENC_B DIGIN DIGIN DIGIN Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used Not to be used X20 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Description 24 VDC supply 0V Encoder 24 VDC Encoder 0 V Encoder Phase A Encoder Phase B Synch switch 24 VDC 0V Synch switch digital input 16 Product Manual IRB 2400 www.com The document is for study only.Installation and Commissioning Connector X20 .if tort to your rights.com EMail:cadserv21@hotmail. 16 digital 24V inputs divided into groups of 8.please inform us. chapter 3.16. Technical data See Product Specification IRB 2400.Connecting Signals Installation and Commissioning 3. see 3.if tort to your rights.X4 Status LED’s OUT IN X1 1 X3 1 16 1 16 16 1 16 X4 MS NS OUT 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 IN X2 12 1 X5 CAN-connection.cadfamily. The groups are galvanically isolated. Topic: Controller. Circuit diagram. CONNECTION TABLE Customer contacts: X1 . Supply to customer switches can be taken either from the cabinet 24 V I/O or from a separate supply.8 Relay I/O DSQC 332 16 output relays each with a single Normal Open contact.3 76 Product Manual IRB 2400 www. Further information For setup parameters. see chapter 11.com EMail:cadserv21@hotmail. section System Parameters. see User’s Guide.we will delete .16.10.com The document is for study only. independent of each other. com The document is for study only.please inform us. supply Signal name Out ch 9a Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b X2 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Product Manual IRB 2400 www.cadfamily.Installation and Commissioning Connecting Signals X1 Unit function Signal name Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8b Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Customer conn.we will delete 77 .if tort to your rights.com EMail:cadserv21@hotmail. X4 Customer conn.we will delete . causes a short rush of current when setting the input.5 mA (at 24V) on the digital inputs. isol.com EMail:cadserv21@hotmail. a serial resistor (100 Ω) may be used. 24 V Signal name In ch 9 In ch 10 In ch 11 In ch 12 In ch 13 In ch 14 In ch 15 In ch 16 0V 0V for in 9-16 Not used Not used Not used Not used Not used Not used Not used Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal name In ch 1 In ch 2 In ch 3 In ch 4 In ch 5 In ch 6 In ch 7 In ch 8 0V for in 1-8 Not used Not used Not used Not used Not used Not used Not used Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NOTE! The input current is 5.cadfamily. 78 Product Manual IRB 2400 www. When connecting a source (PLC). to prevent disturbances. sensitive to pre-oscillation current.Connecting Signals Installation and Commissioning X3 Unit function Opto.com The document is for study only.if tort to your rights.please inform us. A capacitor connected to ground. see 3.we will delete 79 .10.9 Digital 120 VAC I/O DSQC 320 Technical data See Product Specification IRB 2400.X4 Status LED’s 1 2 3 4 5 6 7 8 OUT IN MS NS OUT 9 10 11 12 13 14 15 16 IN X2 X1 1 X3 1 16 1 16 16 1 16 X4 12 1 X5 CAN-connection. see User’s Guide. Further information For setup parameters. Circuit diagram. chapter 3.16.com The document is for study only.Installation and Commissioning Connecting Signals 3.please inform us.if tort to your rights.cadfamily.com EMail:cadserv21@hotmail. section System Parameters. Topic: Controller. CONNECTION TABLE Customer contacts: X1 .16.3 Product Manual IRB 2400 www. see chapter 11. com EMail:[email protected] Signals Installation and Commissioning X1 Unit function Opto isol. AC supply Signal name Out ch 9a Out ch 9b Out ch 10a Out ch 10b Out ch 11a Out ch 11b Out ch 12a Out ch 12b Out ch 13a Out ch 13b Out ch 14a Out ch 14b Out ch 15a Out ch 15b Out ch 16a Out ch 16b Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal name Out ch 1a Out ch 1b Out ch 2a Out ch 2b Out ch 3a Out ch 3b Out ch 4a Out ch 4b Out ch 5a Out ch 5b Out ch 6a Out ch 6b Out ch 7a Out ch 7b Out ch 8a Out ch 8b Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 80 Product Manual IRB 2400 www.we will delete . X2 Customer conn.if tort to your rights.com The document is for study only.cadfamily.please inform us. com EMail:[email protected] inform us.we will delete 81 .Installation and Commissioning Connecting Signals X3 Unit function Opto isol.cadfamily. X4 Customer conn.if tort to your rights. AC N Signal name In ch 9a In ch 9b In ch 10a In ch 10b In ch 11a In ch 11b In ch 12a In ch 12b In ch 13a In ch 13b In ch 14a In ch 14b In ch 15a In ch 15b In ch 16a In ch 16b Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal name In ch 1a In ch 1b In ch 2a In ch 2b In ch 3a In ch 3b In ch 4a In ch 4b In ch 5a In ch 5b In ch 6a In ch 6b In ch 7a In ch 7b In ch 8a In ch 8b Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Product Manual IRB 2400 www.com The document is for study only. Customer terminals: X8 and X9 X8 Signal name LINE1 (blue) LINE2 (clear) shield cabinet ground Pin 1 2 3 4 Remote I/O in Signal name blue clear shield cabinet ground X9 Pin 1 2 3 4 Remote I/O out X5 Device net input and ID connector X5 X9 RIO out POWER NS MS CAN Tx CAN Rx NAC STATUS X5 Not to be used X8 DSQC 350 ABB Flexible Automation RIO in Device Net connector X5. see chapter 11. chapter 3. Topic: Controller. see section 3.1 RIO (Remote Input Output).we will delete .if tort to your rights.17 Field bus units 3. remote I/O for Allen-Bradley PLC DSQC 350 The RIO-unit can be programmed for 32. The RIO-unit should be connected to an Allen-Bradley PLC using a screened. Circuit diagram. Technical data See Product Specification IRB 2400. see User’s Guide.Connecting Signals Installation and Commissioning 3.17.10 and Allen-Bradley RIO specification. two conductor cable.please inform us.com EMail:[email protected] on page 63 Figure 53 RIO-unit 82 Product Manual IRB 2400 www. section System Parameters.16. Further information For setup parameters. 64.cadfamily.com The document is for study only. 96 or 128 digital inputs and outputs. com The document is for study only.cadfamily. LED Status etc. The robot may communicate with the Allen Bradley system only. RIO communication concept Allen Bradley control system Robot 1 .please inform us. 3 or 4 robots. Allen-Bradley Company. Inc. Each of these robots will then have the same rack address.64 in / 64 out Quarter 1 Quarter 2 Rack ID 13 (example) Rack size 2 Starting quarter 1 Robot 3 . the inputs to the robot may come from the Allen Bradley system while the outputs from the robot control external equipment via general I/O addresses and the Allen Bradley system only reads the outputs as status signals. Each quarter provides 32 inputs and 32 outputs and a rack will subsequently provide 128 inputs and 128 outputs.if tort to your rights. A rack may also be shared by 2. All warranty and support services for this product are the responsibility of and provided by ABB Flexible Automation. each robot connected to the Allen Bradley system will occupy 1 rack. Each rack is divided into 4 sections called Quarters. The rack address.64 in / 64 out Quarter 3 Quarter 4 Rack ID 13 (example) Rack size 2 Starting quarter 3 64 in / 64 out 64 in / 64 out Other systems Quarter 1 Quarter 2 Quarter 3 Quarter 4 Figure 54 RIO communication concept . The illustration above shows an example where Robot 1 uses a full rack while robot 2 and robot 3 share 1 rack. but different starting quarters must be specified. Product Manual IRB 2400 www. starting quarter and other required parameters such as baud rate.we will delete 83 .Installation and Commissioning Connecting Signals When the robot is last in a RIO loop. Basically. does not warrant or support this product. are entered in the configuration parameters. Inc.com EMail:cadserv21@hotmail. For example. This product incorporates a communications link which is licensed under patents and proprietary technology of Allen-Bradley Company. the loop must be terminated with a termination resistor according to Allen-Bradley’s specification.128 in / 128 out Quarter 1 Quarter 2 Quarter 3 Quarter 4 Rack ID 12 (example) Rack size 4 Starting quarter 1 128 in / 128 out Robot 2 . or be used in combination with I/O system in the robot.Principle diagram The Allen Bradley system can communicate with up to 64 external systems. Each of these systems is called a Rack and is given a Rack Address 0-63. DSQC 351 84 Product Manual IRB 2400 www.we will delete DSQC 351 Interbus-S CAN Rx CAN Tx MS NS POWER ABB Flexible Automation .16. The lenght code depends on the selected data. see User’s Guide. section System Parameters. Further information For setup parameters. see section 3. Customer terminals: see figure below regarding locations.com The document is for study only. Circuit diagram. slave DSQC 351 The unit can be operated as a slave for a Interbus-S system.if tort to your rights.2 Interbus-S.17.please inform us. X20 Interbus-S in X21 Interbus-S out X20 RC BA RBDA POWER X21 X5 X3 X5-DeviceNet input and ID connector X3 Interbus-S supply Device Net connector X5.3 on page 63 Figure 55 Interbus-S.Connecting Signals Installation and Commissioning 3. Width between 1 and 4. Unit ID to be entered in the Interbus-S master is 3.com EMail:[email protected]. see chapter 11. Topic: Controller. Technical data See Interbus-S specification. 3 Word 1. The Interbus-S system can communicate with a number of external devices. The Interbus-S inputs and outputs are accessible in the robot as general inputs and outputs.11 Word 8. X20 Pin 1 2 3 4 5 6 7 8 9 Interbus-S IN 1 5 6 9 Signal name TPDO1 TPDI1 GND NC NC TPDO1-N TPDI1-N NC NC Description Communication line TPDO1 Communication line TPDI1 Ground connection Not connected Not connected Communication line TPDO1-N Communication line TPDI1-N Not connected Not connected Product Manual IRB 2400 www.cadfamily.com EMail:[email protected] IN Connecting Signals 64 in/64 out Robot 3 2 .please inform us. (The last unit in the chain does not have cable connected and thereby no link).we will delete 85 . The link is used to inform the Interbus-S unit that more units are located further out in the chain. For application data.7 Word 4. refer to Interbus-S.Installation and Commissioning Communication concept 128 in/128 out Master PLC Robot 1 .com The document is for study only. DIN 19258.11 IN *1 OUT OUT Figure 56 Outline diagram. *1 Note that there is a link between pin 5 and 9 in the plug on interconnection cable which is connected to the OUT connector for each unit. the actual number depends on the number of process words occupied of each unit.if tort to your rights.3 IN OUT *1 Robot 1 2 . International Standard. The robot can be equipped with one or two DSQC 351. we will delete .com The document is for study only.please inform us.cadfamily.if tort to your rights.Connecting Signals Installation and Commissioning Interbus-S OUT 5 1 9 6 Signal name TPDO2 TPDI2 GND NC +5V TPDO2-N TPDI2-N NC RBST X21 Pin 1 2 3 4 5 6 7 8 9 X3 Pin 1 2 3 4 5 Description Communication line TPDO2 Communication line TPDI2 Ground connection Not connected +5VDC Communication line TPDO2-N Communication line TPDI2-N Not connected Synchronization Interbus-S supply 5 1 Signal name 0 V DC NC GND NC + 24 V DC Description External supply of Interbus-S Not connected Ground connection Not connected External supply of Interbus-S NOTE! External supply is recommended to prevent loss of fieldbus at IRB power off.com EMail:cadserv21@hotmail. 86 Product Manual IRB 2400 www. com EMail:[email protected] will delete 87 . DSQC352 The unit can be operated as a slave for a Profibus-DP system.com The document is for study only.please inform us. Customer connections X20 Profibus connection X20 PROFIBUS ACTIVE X5 X3 X5 . slave.if tort to your rights. Technical data See Profibus-DP specification.3 Word 1:8 Robot 1 1 . see chapter 11. Circuit diagram. Further information For setup parameters.Installation and Commissioning Connecting Signals 3.17.11 Word 17:24 *1 Figure 58 Profibus-DP communication concept DSQC 352 Profibus NS MS CAN Tx CAN Rx POWER ABB Flexible Automation *1 Product Manual IRB 2400 www. Topic: IO Signals.3 Profibus-DP. section System Parameters. see User’s Guide. DIN E 19245 part 3.cadfamily.DeviceNet connector X3 .7 Word 9:16 128 in/128 out 2 Robot 2. location of connectors Communication concept 256 in/256 out Master PLC Robot 1 .Power connector Figure 57 DSQC352. see section 3.please inform us. refer to Profibus-DP. For application data. The Profibus-DP inputs and outputs are accessible in the robot as general inputs and outputs.3 on page 63.Connecting Signals Installation and Commissioning The Profibus-DP system can communicate with a number of external devices.we will delete . International Standard.cadfamily. The robot can be equipped with one or two DSQC352.com The document is for study only. *1 . The actual number depends on the number of process words occupied of each unit.com EMail:[email protected] that the Profibus cable must be terminated in both ends.if tort to your rights. DIN 19245 Part 3. 88 Product Manual IRB 2400 www.16. X20 Pin 1 2 3 4 5 6 7 8 9 Profibus-DP 5 1 9 6 Signal name Shield NC RxD/TxD-P Control-P GND + 5V DC NC Rxd/TxD-N NC Description Cable screen Not connected Receive/Transmit data P Ground connection Not connected Recieve/Transmit data N Not connected Profibus-DP supply 5 1 Signal name 0 V DC NC GND NC + 24 V DC X3 Pin 1 2 3 4 5 Description External supply of Profibus-DP Not connected Ground connection Not connected External supply of Profibus-DP Device Net connector X5. type Phönix Combicon MSTTBVA 2. Two variants exits depending on backplane type. SIO The robot has two serial channels. computers and other equipment (see Figure 59). see User’s Guide. on controller backplane:X1(SIO1) and X2(SIO2). chapter 3. The serial channels are: .com EMail:cadserv21@hotmail. section System Parameters. see 3.if tort to your rights.1 Serial links.08. outline diagram. which can be used by the customer to communicate with printers. transmission speed 300 . see chapter 11. Separate documention is included.cadfamily. SLIP.18. Product Manual IRB 2400 www. Cable connectors with screwed connections (not supplied). Circuit diagram. chapter 11.please inform us. Product Specification IRB 2400.we will delete 89 . RXD4.7. Topic: Controller.Installation and Commissioning Connecting Signals 3.19 200 baud. TXD4-N.5/12-6-5.SIO2RS 422 full duplex TXD4.18 Communication 3. transmission speed 300 .SIO1RS 232 with RTS-CTS-control and support for XON/XOFF.when the option RAP Seriel link is ordered. Customer terminals. terminals.19 200 baud. RXD4-N. External computer Figure 59 Serial channels.10. Keying of board connector according to circuit diagram. . Further information For setup parameters.com The document is for study only. if tort to your rights.com EMail:cadserv21@hotmail. RXD=Receive Data. DCLK=Data Transmission Clock. 90 Product Manual IRB 2400 www. CTS=Clear To Send. DSR=Data Set Ready. DTR=Data Terminal Ready.cadfamily.Connecting Signals DSCQ 330 (screw terminals) X1 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Signal TXD RTS N 0V RXD CTS N 0V DTR DSR 0V X2 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Installation and Commissioning Signal TXD TXD N 0V RXD RXD N 0V DATA DATA N 0V DCLK DCLK N 0V DSQC 369 (D-sub connectors) X1 Pin 1 2 3 4 5 6 7 8 9 RXD TXD DTR 0V DSR RTS N CTS N Signal X2 Pin 1 2 3 4 5 6 7 8 9 Signal TXD TXD N RXD RXD N 0V DATA DATA N DCLK DCLK N Explanation of signals: TXD=Transmit Data. DATA=Data Signals in Half Duplex Mode.we will delete .please inform us.com The document is for study only. RTS=Request To Send. Maximum node-to-node distance 100 meter. DSQC 336 The ethernet communication board has two options for ethernet connection. on board front: X4 and X11 External computer LAN TXD RXD Controller Robot 1 Controller Robot 2 etc.2 Ethernet communication. Thinwire Enet.18. Product Manual IRB 2400 www. Circuit diagram. Connector X11 is used for connection of transceivers with AUI (Attachment Unit Interface). i. see chapter 11.when the option Ethernet services is ordered. section System Parameters.com EMail:cadserv21@hotmail. Connector X4 is used for connection of twisted-pair Ethernet (TPE).we will delete 91 . outline diagram.3 : 10BASE-T. Typical use of this connector is connection of transceivers for 10BASE2 (CheaperNet. 50 ohm coax with BNC connector) or optical fibre net. The ethernet communication board has no termination for cable screen. Thinnet.2 inch. see User’s Guide. Customer terminals.com The document is for study only.if tort to your rights. connected via a HUB. Further information For setup parameters. or as defined in IEEE 802. Technical data See Ethernet specification.cadfamily. +70o C...e.AUI connection DSQC 336 F T P E X4 .0.TPE connection Ethernet HUB C O N S O L E Figure 60 Ethernet TCP/IP. Topic: Controller. 10BASE-T is a point-to-point net. Cable screen must be grounded at cabinet wall with a cable gland. . Note the environmental conditions for the transceiver inside the controller.Installation and Commissioning Connecting Signals 3. CAN NS MS A U I X11 .please inform us. Separate documentation is included. if tort to your rights.please inform us.cadfamily.Ethernet AUI connector X11 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 8 9 1 Signal name GND COLL+ TXD+ GND RXD+ GND NC GND COLLTXDGND RXD+12V GND NC Description Ground connection Collision detection line + Transmit data line + Ground connection Receive data line + Ground connection Not connected Ground connection Collision detection line Transmit data line Ground connection Receive data line +12VDC Ground connection Not connected 92 Product Manual IRB 2400 www.com The document is for study only.we will delete .Connecting Signals Installation and Commissioning Connector X4 .com EMail:[email protected] TPE connector X4 Pin 1 2 3 4 5 6 7 8 1 8 Signal name TPTX+ TPTXTPRX+ NC NC TPRXNC NC Description Transmit data line + Transmit data line Receive data line + Not connected Not connected Receive data line Not connected Not connected Connector X11 . 19 External operator’s panel All necessary components are supplied.cadfamily. IP 54. except for the external enclosure.com The document is for study only. in accordance with IEC 144 and IEC 529.we will delete 93 . The assembled panel must be installed in a housing which satisfies protection class. M4 (x4) M8 (x4) 45o 196 Required depth 200 mm 193 223 180 224 240 70 62 96 Holes for flange 140 184 External panel enclosure (not supplied) 200 Holes for operator’s panel Teach pendant connection Holes for teach pendant holder 90 Connection to the controller 5 (x2) 155 Figure 61 Required preparation of external panel enclosure.if tort to your rights.com EMail:cadserv21@hotmail. Product Manual IRB 2400 www.please inform us.Installation and Commissioning Connecting Signals 3. cadfamily.Connecting Signals Installation and Commissioning 94 Product Manual IRB 2400 www.please inform us.we will delete .com EMail:[email protected] tort to your rights.com The document is for study only. 4. are coming up.1. Robots within the same family (i. offsets from manufacturing calibration. connect the batteries and start the installation according to 4.Silent = The installation follows the information on the Key disk. Insert the “Key disk” when displayed on the teach pendant. • Manipulator parameters (one disk) Includes sync.1 Installation procedure 1.please inform us. If not. make sure that the correct robot type is entered. not included in the system pack.com The document is for study only. If Query is selected.we will delete 95 . 4. which means that the control program and settings (pre-installed) are saved when the power supply to the robot is switched off. different variants of the robot) can use the same key disk with a licence number. System Parameters etc. • Controller parameters (one disk) At delivery. it includes I/O configuration according to order specification. The robot might be delivered without software installed and the memory back-up batteries disconnected to ensure maximum battery capacity after installation. gain access to service mode. robot type (within the same family).e. Makes it possible to exclude options but not add more than included in the Key disk. see User’s Guide. this will affect the safety function Reduced speed 250 mm/s.1. all options and ProcessWare. . Keep attention to prompted System pack disk number (all diskettes are not used at the same installation). • System pack BaseWare OS. Product Manual IRB 4400 www. Perform a cold start on the system.1. If so.if tort to your rights.Query = Questions about changing language. 2.cadfamily. During the installation following menus appears: . 3. are possible to add. Follow information displayed on the teach pendant. . At commissioning all parameters are stored.Add Opt =The installation follows the Key disk but further options.1 System diskettes • Key disk (one disk) Each robot needs an unique key disk with selected options and IRB type.Installation and Commissioning Installing the Control Program 4 Installing the Control Program The robot memory is battery-backed.com EMail:cadserv21@hotmail. After the control program has been installed.if tort to your rights.1.com The document is for study only. 5. make sure that all required options are installed. Rejecting of proposed options during installation may cause an incomplete robot installation. For identification.we will delete . Load the specific installation parameters from the Controller Parameter disk or corresponding. You will find the article number for the DC-link on the unit inside the controller. Note that some of these options also require installation of other options.16. The robot performs a warm start when installation is finished. 4. The warm start can take up to 2 minutes after the installation display ready. Type DSQC 345A DSQC 345B DSQC 345C DSQC 345D DSQC 358C DSQC 358E Art.cadfamily. please see label attached at the top of the units. 6. 4. 4. the diskettes should be stored in a safe place in accordance with the general rules for diskette storage.16.2 Calibration of the manipulator Calibrate the manipulator according to section 2. step down DC-link + single drive unit DC-link + single drive unit Description For IRB 6400 you will also get a question on what type of balancing unit that is used. Wait until the welcome window appears on the display before doing anything. 96 Product Manual IRB 4400 www.please inform us.com EMail:[email protected] the Control Program Installation and Commissioning If Query is selected. no 3HAB 8101-1 3HAB 8101-2 3HAB 8101-3 3HAB 8101-4 3HAB 8101-10 3HAB 8101-12 Config id DC0 DC1 DC2 DC3 DC2T DC2C DC-link DC-link DC-link DC-link.2.2 Question about used DC-links and balancing units You will get a question about used DC-link. Conclude the installation with updating the revolution counters according to section 2. Do not store the diskettes inside the controller to avoid damaged from heat and magnetic fields. below there is a list of avaible DC-links. Just wait until the robot starts the Installation dialog.com The document is for study only. Continue with following the text on the teach pendant. Select File: Restart 3. Press the key C-Start It will take quite some time to perform a Cold start.cadfamily. 5. Select the Service window 2. Do not touch any key. Enter the numbers 1 4 7 4.Installation and Commissioning Installing the Control Program 4. options and IRB types (Valid for robots within the same family) 1.1. see 4. Then enter the numbers 1 3 4 6 7 9 4. Select the Service window 2.if tort to your rights.we will delete 97 . 4.1. Besides disconnecting the batteries for a few minutes. Select File: Restart 3. The fifth function key changes to I-Start Note! Make sure that the disk 3 from the System pack is inserted when installing BaseWare OS Plus or disk 5 when installing BaseWare OS.com EMail:[email protected] inform us.4 How to change language. joystick.3 Cold start To install the control program in a robot already in operation the memory must be emptied. Product Manual IRB 4400 www. the following method can be used: 1. Press the key I-Start 6. enable device or emergency stop until you are prompted to press any key. The fifth function key changes to C-Start (Cold start) 5. 3. 1.please inform us. 2.com EMail:cadserv21@hotmail. Press OK. Save the new parameters according to section 4. Controller Parameter. Manipulator Parameters The S4C controller does not contain any calibration information at delivery (Robot Not Calibrated shown on the teach pendant). 3.com The document is for study only.6. 2. 4. Manipulator Parameters.5 How to use the disk. remember to connect the back-up batteries. Select File:Add or Replace Parameter. Do not select Add new or Load Saved Parameters. Select File:Add New Parameters.Installing the Control Program Installation and Commissioning 4. The basic parameters are loaded at the cold start. Controller Parameters.6. Once the Manipulator Parameter disk contents has been loaded to the controller as in one of the two cases described below. 1. should a new parameter back-up be saved on the disk. Manipulator Parameters. Load the calibration offset values from the disk.if tort to your rights. Controller Parameter the Manipulator Parameter disk is no longer needed.1 Robot delivered with software installed In this case the basic parameters are already installed. Save the new parameters according to section 4. After saving the new parameters on the disk. 4.cadfamily.5. Press OK. 5. Press OK. The delivery specific I/O configuration is loaded from the disk. Load the calibration offset values from the disk.2 Robot delivered without software installed In this case a complete cold start is necessary.we will delete . 98 Product Manual IRB 4400 www. Do not select Add new or Load Saved Parameters.5. 4. 6. Select File: Add or Replace Parameter. if tort to your rights.com EMail:cadserv21@hotmail. System Parameters. Product Manual IRB 4400 www.we will delete 99 . Controller Parameter. Select File:Save All As.Installation and Commissioning Installing the Control Program 4. For more detailed information regarding saving and loading parameters see User’s Guide.com The document is for study only.cadfamily. Insert the disk. 2.6 Saving the parameters on the Controller Parameter disk 1.please inform us. Installing the Control Program Installation and Commissioning 100 Product Manual IRB 4400 www.please inform us.com EMail:[email protected] will delete .cadfamily.com The document is for study only.if tort to your rights. if tort to your rights.we will delete 101 . Product Manual IRB 2400 www. The drive and measurement systems each consist of two systems. External drive units are mounted in a user designed cabinet. The configuration files are optimum designed concerning system behaviour and performance of the axes.com The document is for study only. so a combination of standard files can be used. Each system is connected to the CPU boards via a serial communication link.please inform us. Internal drive units are mounted either inside the robot cabinet or in a separate external cabinet. Allowed combinations . Internal drive units mounted in a separate cabinet cannot be combined with external drive units.cadfamily.1 General External axes are controlled by internal or external (equals to non ABB) drive units. A number of template configuration files are supplied with the system. Axes connected to Measurement System 1 can use Drive System 2 and vice versa.5.see configuration files section 5.Installation and Commissioning External Axes 5 External Axes 5.com EMail:[email protected]. When installing external axes it is important to design installations. A maximum number of 6 external axes can be controlled by S4C. IRB 2400. Contains no CPU IRB Drive System 2 inside external axes cabinet Drive System 2 inside user designed cabinet (non ABB drives) Measurement System 1 Figure 62 Outline diagram.cadfamily. One extra serial measurement board (SMB) can be connected to Measurement System 1 and up to four to Measurement System 2.com EMail:cadserv21@hotmail. IRB 640 and IRB 840/A).e. This axis is connected to the drive unit located in the DC-link (not applicable to robots using DC-link DSQC 345D. Max one external axis can be connected to Drive System 1. IRB 340. as IRB 1400. Drive System 2 is in most cases located in a separate external cabinet. a drive system 2 can be located in the robot cabinet. IRB 640 and IRB 840/A.if tort to your rights. One of the extra serial measurement boards of system 2 can be located inside the robot cabinet. inside robot cabinet alt. In this case no external drive units or internal drive units mounted in a separate cabinet can be used.com The document is for study only. i.please inform us. Up to six external axes can be connected to Drive System 2.2 . external axes.we will delete .External Axes Installation and Commissioning Measurement System 2 Drive System 1. This mixed system is called Drive System 1. For robots using only two drive units. 102 Product Manual IRB 2400 www. Two axes can be connected to the drive module. See Figure 62. .Installation and Commissioning External Axes 5. .com The document is for study only. Different sizes of motors available. .Connection box with serial measurement board. These kits contain all parts needed to install and operate external axes.All cables with connectors. . manual brake release and terminal block for limit switches.please inform us. The kit contains: . .Configuration file for easy software installation.if tort to your rights.Documentation. For more information see Product Specification Motor Unit from ABB Flexible Automation documentation. Product Manual IRB 2400 www.we will delete 103 .Motor/motors with brake and resolver.Gear boxes.2 Easy to use kits A number of easy to use kits are available by ABB Flexible Automation AB.cadfamily.com EMail:cadserv21@hotmail. 1 DMC-C Atlas Copco Controls stand alone servo amplifier DMC-C can be connected to Drive System 2.if tort to your rights.3.please inform us.com The document is for study only.com EMail:cadserv21@hotmail. Drive System 2 Atlas DMC Atlas Copco Atlas DMC Atlas Copco Atlas DMC Atlas Copco Mesurement System 2 IRB Serial measurement board Figure 63 Servo amplifier.cadfamily. Total of max 6 external axes can be installed.we will delete . DMC. Atlas Copco Controls provides the information on suitable motors and how to make installation and commissioning. 104 Product Manual IRB 2400 www.External Axes Installation and Commissioning 5. see Figure 63.3 User designed external axes 5. For further information about DMC-C and FBU contact Atlas Copco Controls.com The document is for study only.if tort to your rights.10 V) or a field bus.Installation and Commissioning External Axes 5.2 FBU Atlas Copco Controls FBU (Field Bus Unit) can handle up to 3 external drive units.please inform us. Drive System 2 Mesurement System 2 Atlas DMC Atlas Copco S E R V O S E R V O S E R V O IRB Serial measurement board Figure 64 Field bus unit. Product Manual IRB 2400 www.3. The drive units can be connected to analog speed reference outputs (+/. FBU.we will delete 105 .com EMail:[email protected]. see Figure 64. Each system is connected to the CPU board via a serial link. Up to 6 external axes can be connected to those boards. The external axis must be connected to node 4 and in the configuration file be addressed as logical node 7. one used for the robot manipulator. A special configuration can be used with no robot connected. A battery supplies the SMB with power during power fail. No gaps may occur in the number sequence. the physical connection node must also be unique. normally a track motion. After power on the system is ready for operation without any synchronization procedure.com EMail:cadserv21@hotmail. The serial link is of ring type with board 1 connected to CPU-board serial output. Measurement System 2 can consist of one to four SMB boards.External Axes Installation and Commissioning 5. See configuration files in Figure 78. Only Measurement System 1 with one or two SMB may be used. While the node number is the same as physical connection.com The document is for study only.cadfamily.we will delete .3. If the axes move during power fail the internal revolution counters are automatically updated. 106 Product Manual IRB 2400 www. 1 and 2.please inform us.This link also supplies power to the SMB. Each SMB has 6 connection nodes for resolvers. MEASUREMENT SYSTEM 1 configuration files MN4M1Dx MEASUREMENT SYSTEM 2 configuration files MNxM2Dx Robot manipulator Serial Measurement Board 1 6 resolvers CPU Serial Measurement Board 1 Measurement S System 2 serial communication CPU Measurement System 1 serial communication Serial Measurement Board 2 Max 6 resolvers (5 if one axis connected to Measurement ). The last Serial Measurement Board (SMB) is connected to the CPU-board serial input. System 1) Serial Measurement Board 2 node 4 1 resolver Serial Measurement Board 3 Serial Measurement Board 4 Figure 65 Measurement systems. The board numbering always starts with board 1. the other one for one external axis.3 Measurement System There are two measurement system systems. Measurement System 1 can consist of up to two SMB.if tort to your rights. Every axis connected to a measuring system must have an unique node number. no robot) configuration files ACxM1D1 (Measurement System 2 may not be used together with this configuration) CPU Serial Measurement Board 1 Measurement System 1 serial communication Max 6 resolvers Serial Measurement Board 2 Figure 66 Measurement system 1. 5766 388-5. Resolver Each resolver contains two stators and one rotor. Technical data Resolver Integrated in motor of IRB type or art. EXC* 0v EXC* Stator X X* 0V X* * See connection table Rotor Stator Y Y* 0V Y* Figure 67 Connections for resolvers. size 11 Resolver must be approved by ABB for reliable operation.no. direct drive max 30 m (X. with shield.com The document is for study only.Installation and Commissioning External Axes MEASUREMENT SYSTEM 1 (only external axes. 107 Motor to resolver gear ratio Resolver cable length: Cable: AWG 24.please inform us.if tort to your rights. Product Manual IRB 2400 www.com EMail:cadserv21@hotmail. connected as shown in Figure 67.cadfamily.we will delete . Y for each resolver) total max 70 m for EXC signals. 1:1. max 55pF/m. The cabling must comply with signal class “measurement signals” (see chapter 3. measurement boards and resolvers is essential. It is very important that the noise level on the measurement signals from the external axes is kept as low as possible. The EXC. Correct shielding and ground connections of cables.cadfamily.if tort to your rights. Y. parallel connected. Signal classes).please inform us. The enclosure for external serial measurement board(s) must comply with enclosure class IP 54.com EMail:cadserv21@hotmail. Measurement System 2.External Axes Installation and Commissioning The X. 0V EXC are used for common supply for all resolvers. Resolver.com The document is for study only. connector on robot cabinet wall (option: 386 . board 1 Node 1 EXC1 0V EXC1 EXC2 0V EXC2 X Y 0V X 0V Y B1 C1 B2 C2 B3 C3 B4 C4 B5 C5 B6 C6 A1 A2 Node 2 A3 A4 Node 3 A5 A6 A8 A9 B8 C8 B9 C9 A10 A11 B10 C10 B11 C11 A12 A13 B12 C12 B13 C13 Node 4 Node 5 Node 6 108 Product Manual IRB 2400 www. 0V X and 0V Y signals are used to connect resolvers to a serial measurement board. mounted inside robot cabinet) XS27.External Axes Measurement Board.1.we will delete . to prevent bad performance. in accordance with IEC 144 and IEC 529. please inform us.SMB 3-6 D-Sub 25 socket +BAT 0V BAT GND BATLD 0V SDO-N SDI-N +BATSUP +24V SDO SDI GND 0V EXC1 0V EXC1 Y2 X2 Y1 X1 EXC1 EXC1 0V Y2 0V X2 0V Y1 0V X1 GND X1 Y1 X2 Y2 0V EXC1 0V EXC1 0V EXC1 X3 Y3 X4 Y4 0V EXC2 0V X1 0V Y1 0V X2 0V Y2 EXC1 EXC1 EXC1 0V X3 0V Y3 0V X4 0V Y4 EXC2 GND X4 Y4 X5 Y5 0V EXC2 0V EXC2 0V EXC2 X6 Y6 X3 Y3 0V EXC1 0V X4 0V Y4 0V X5 0V Y5 EXC2 EXC2 EXC2 0V X6 0V Y6 0V X3 0V Y3 EXC1 Product Manual IRB 2400 www.SMB D-Sub 9 pin R2.if tort to your rights.Installation and Commissioning External Axes Resolver.com The document is for study only.com EMail:[email protected] R2.SMB 1-2 D-Sub 15 socket R2.we will delete 109 .cadfamily. connectors on Measurement Board DSQC 313 Contact/ point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R2.SMB 1-4 D-Sub 25 pin R2. 3. They CANNOT be combined with internal controlled drive units connected to drive system 2. The rectifier DSQC 358C has in addition to its rectifier section also a drive inverter for one external axis. an extra drive unit can be placed in the S4C robot cabinet. 6 may not be connected to the same drive unit.3.SMB R2. Each system is connected to the CPU board via a serial link. This rectifier can be used in all S4C robot cabinets except for those robots needing the DSQC 345D rectifier (IRB 640 and IRB 840/A). In section 5. Up to 6 external axis can be connected using DMC’s and/or FBU’s. see documentation for the separate enclosure.External Axes Installation and Commissioning R2.com The document is for study only.SMB 1-2 Serial Measurement Board (SMB) SDO SDI +BAT 0V BAT BATLD BATSUP +24 V 0V serial communication output serial communication input battery + battery 0 V not to be used not to be used EXC1 24 V power EXC2 0 V power X1 excitation power to resolver 1. As an option it’s possible to use Atlas DMC of FBU. 110 Product Manual IRB 2400 www.G R2.2. If the function “common drive” is to be used. but use the Drive System 1 rectifier.4 Drive System There are two drive systems 1 and 2.2.we will delete .5. For information on fuses. If drive unit with three drive inverters (nodes) are used. The link also supplies low voltage logic power to the rectifier and drive modules.cadfamily.please inform us.com EMail:[email protected] Input x-stator node 1 5. a contactor unit for motor selection is required. 3 or 4.SMB 3-6 R2.SMB 1-4 R2. Each drive system has its own transformer. Those units are always connected to drive system 2 and measurement system 2.3 excitation power to resolver 4.5 there is a complete list of template files for external controlled axes. For robots using two drive units. This drive unit is connected to the Drive System 2 serial communication link. 2. power contactors etc.if tort to your rights. This combined system is called Drive System 1. axes with measurement node 1. 5. the max allowed power consumption of these axes are 0. • Max/rated current from drive unit (sum of all inverters on same drive unit). DRIVE SYSTEM 1 Drive System 1 serial communication DRIVE SYSTEM 2 Drive System 2 serial communication External axis drive system 1 (1 axis) Unit number 0 Robot axes 3 2 1 Unit number 0* 3* 2* 1* External axes drive system 2 (5-6 axes) Transformer 1 Figure 68 Drive systems with external cabinet. • Max/rated current from dc-link. Note: For safety reasons. • Max/rated current from drive inverter.5 kW.Installation and Commissioning When designing the drive system following has to be checked: External Axes • Max motor current.com EMail:cadserv21@hotmail. in order not to demagnetize the motor.com The document is for study only. • Max/rated power from transformer. Transformer 2 Product Manual IRB 2400 www.if tort to your rights.please inform us. the power supply to the external motor must be switched off when the robot is in the MOTORS OFF mode.we will delete 111 . Drive system configuration with one external axis at Drive System 1 in S4C robot cabinet and five to six axes at Drive System 2 installed in external cabinet. • Max/rated power for bleeder. Note: If the system contains axes with no stand by state (the axes will continue to be controlled while the brakes are activated for the robot).cadfamily. 112 Product Manual IRB 2400 www.External Axes Installation and Commissioning Drive system configuration with one external axis at Drive System 1 and two or three axes at Drive system 2.cadfamily.we will delete .com The document is for study only.2 Drive System 2 serial communication Drive System 1 serial communication DC-link (optional with driver inverter) Drive unit * Unit number for drive system 2 External axis drive system 1 (1 axis) Unit number 0 0* 2 1 Robot axes External axis drive system 2 (2-3 axes) Transformer 1 Figure 69 Drive system installed in the S4C cabinet.please inform us.com EMail:cadserv21@hotmail. Technical data Drive System Max current (A) DSQC 345C / DC2 DSQC 358C / DC2T DSQC 358E / DC2C DSQC 345D / DC3 Rated current (A) Max bleeder power (kW) 15.3 Rated bleeder power (kW) 0.7 275 370 Figure 70 Rectifier units. DRIVE SYSTEM 1.3 15.if tort to your rights. all installed in the S4C robot cabinet.6 16.9 0.9 Min voltage (V) 80 70 14. 2 11..6 A 3.please inform us.6 A 6.45/5.Node .5/1.3 C Figure 71 Drive units. drive unit DSQC 358C.. current (A RMS)/average current (A RMS)..if tort to your rights.25/1.5/1.8/20. E Product Manual IRB 2400 www.0 D 1.5/30.25/1.8/20.3/5.0 D 6.8/20.3/12.3/5. C Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Node 111 111 222 222 222 Phase UVW UVW UUU VVV WWW X2 Figure 73 Power connections..com The document is for study only. Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Node 111 .com EMail:[email protected] T 11.3/5.7/4.5 G Node 2 3.3/5.8 29..Installation and Commissioning External Axes Unit type DSQC 346A DSQC 346B DSQC 346C DSQC 346G DSQC 358C DSQC 358E Node 1 3.-3 .-3 .. B.0/4.7/16.0 11.25/1.. drive unit DSQC 346A.222 222 222 Phase . drive unit DSQC 246G Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 .U WVU X2 Figure 72 Power connections.W .. max.0 B Total unit 8.2 B 11.3 C 36.3 C Node 3 1.V .UUU VVV WWW X2 Figure 74 Power connections.3 C 29.7/3.1 66..-3 222 Phase WVU .0 T 36.we will delete 113 .cadfamily.6 A 11.0 36. if tort to your rights. Controller R (U) S (V) T (W) XS7 EXT PTC 0 V EXT PTC 0V EXT BRAKE EXT BRAKE REL EXT BRAKE PB Manual brake release Figure 75 Connections of motor.External Axes Installation and Commissioning Motor connection to drive unit. all PTC resistors are connected in series. If a temperature sensor is not used. S-phase (V-phase) and T-phase (W-phase) respectively. EXT PTC This signal monitors the temperature of the motor. If more than one motor is used. external connector Motor current R-phase (U-phase). Technical data Motor Technical data AC synchronous motor 3-phase.please inform us. 4 or 6-pole ABB Flexible Automation can supply further information.com The document is for study only. Motor PTC Brake 114 Product Manual IRB 2400 www. the circuit must be strapped.we will delete .com EMail:[email protected]. A high resistance or open circuit indicates that the temperature of the motor exceeds the rated level. com The document is for study only.if tort to your rights.Installation and Commissioning External Axes XS7.com EMail:[email protected] inform us.we will delete 115 . Connector on S4C robot cabinet wall (option: 391/392/394) Conn. D 0V EXT PTC EXT PTC PTC jumper 1 PTC jumper 1 C M7 T M7 T M7 T PTC jumper 2 PTC jumper 2 M8 T M8 T B M7 S M7 S M7 S LIM 2A LIM 2B M8 S M8 S BRAKE REL 0V BRAKE A M7 R M7 R M7 R LIM 1A LIM 1B M8 R M8 R BRAKE REL BRAKE REL BRAKE PB M9 R M9 R M9 R - 0V BRAKE M9 T M9 T M9 T 0V BRAKE M9 S M9 S M9 S OPTION 391 M7 OPTION 392 M7 M8 OPTION 394 M7 M8 M9 Drive system 1 Drive system 2 2 Drive system 1 2 2 Drive Unit Drive node Node type 0 2 T Drive Unit Drive node Node type 0 2 T 0 1 G Drive Unit Drive node Node type 0 2 T 0 1 G 0 2 T Product Manual IRB 2400 www. Point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Figure 76 Motor connections.cadfamily. Point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 D 0V EXT PTC EXT PTC PTC jumper 1 PTC jumper 1 M10 R M10 R M10 S M10 S M12 R M12R M12 S M12 S M12 T M12 T C M7 T M7 T M7 T PTC jumper 2 PTC jumper 2 M8 T M8 T M10 T M10 T 0V BRAKE M9 T M9 T M9 T M11 T M11 T M11 T B M7 S M7 S M7 S LIM 2A LIM 2B M8 S M8 S BRAKE REL 0V BRAKE 0V BRAKE M9 S M9 S M9 S M11 S M11 S M11 S A M7 R M7 R M7 R LIM 1A LIM 1B M8 R M8 R BRAKE REL BRAKE REL BRAKE PB M9 R M9 R M9 R M11 R M11 R M11 R OPTION 37M : axes M7-M8 OPTION 37N : axes M7-M10 OPTION 37O : axes M7-M12 M7 M8 M9 M10 M11 M12 Drive systemDrive UnitDrive node Node type 2 1 2 T 2 1 1 G 2 2 2 T 2 2 1 G 2 3 2 T 2 3 1 G 116 Product Manual IRB 2400 www.External Axes Installation and Commissioning X7.com The document is for study only. Connector on external cabinet wall (options: 37x) Conn.we will delete .com EMail:[email protected] inform us.if tort to your rights. please inform us. the power supply to the external motor must be switched off when the robot is in the MOTORS OFF mode.cadfamily. Product Manual IRB 2400 www.if tort to your rights. Note: For safety reasons.com EMail:[email protected] will delete 117 .Installation and Commissioning OPTION 37P : axes M7-M9 OPTION 37Q : axes M7-M12 M7 M8 M9 M10 M11 M12 Drive systemDrive UnitDrive node Node type 2 1 1 C 2 1 2 C 2 1 3 B 2 2 1 C 2 2 2 C 2 2 3 B External Axes OPTION 37V : axes M7-M10 OPTION 37X : axes M7-M12 M7 M8 M9 M10 M11 M12 Drive systemDrive UnitDrive nodeNode type 2 1 1 C 2 1 2 C 2 2 2 T 2 2 1 G 2 3 2 T 2 3 1 G Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury.com The document is for study only. Drive system z). Measurement system y. When installing external axes it is important to design installations. Drive system z).please inform us. 118 Product Manual IRB 2400 www.com The document is for study only. For installing and change of parameter data. Note: When using AC files the system must be booted with “No manipulator”. In order to have the possibility to read and change most of the parameters from the teach pendent unit. File names ENxM2D2 (External Node x. see Figure 79. Internal drive units are used. The configuration files are optimum designed concerning system behaviour and performance of the axes.cadfamily.com EMail:cadserv21@hotmail. File names ACxMyDz (Axis Controlled x. Internal drive units are used.External Axes Installation and Commissioning 5. Measurement system 2. • External axes files used in system without robot. section System Parameters. External drive units are used (DMC and FBU). Drive system 2). see Figure 77.if tort to your rights. see the User’s Guide. • External controlled external axis. Topic: Manipulator.5 Configuration Files In order to simplify installation of external axes a number of configuration files are delivered with the system. Four types of configuration files are delivered: • Utility files for defining transformer and rectifier types in drive system 2.3. so a combination of existent files can be used. File names MNxMyDz (Measurement Node x.we will delete . the system must be booted in service mode. Measurement system y. • External axes files used for axes connected to a system with robot. see Figure 78. com EMail:[email protected]. Product Manual IRB 2400 www.Installation and Commissioning External Axes IRB 1400 IRB 2400 IRB 4400 IRB 6400 IRB 640 IRB 840/A Config.please inform us. file Logical axis Measuring system System* Node* 4(7)** 4(7)** 4(7)** System* 1 2 2 Drive system Unit position 0 1 0 Node 2 2 2 X X X X X X MN4M1D1 MN4M1D2 MN4M1D12 7 7 7 1 1 1 X X X X X X MN1M2D1 MN1M2D2 MN1M2D12 8 8 8 2 2 2 1 1 1 1 2 2 0 1 0 2 1 1 X X X X X X MN2M2D1 MN2M2D2 MN2M2D12 9 9 9 2 2 2 2 2 2 1 2 2 0 2 0 2 2 2 X X X X X X MN3M2D1 MN3M2D2 MN3M2D12 10 10 10 2 2 2 3 3 3 1 2 2 0 2 0 2 1 1 X X X X X X MN4M2D1 MN4M2D2 MN4M2D12 11 11 11 2 2 2 4 4 4 1 2 2 0 3 0 2 2 2 X X X X X X MN5M2D1 MN5M2D2 MN5M2D12 12 12 12 2 2 2 5 5 5 1 2 2 0 3 0 2 1 1 X X X X X X MN6M2D1 MN6M2D2 MN6M2D12 7 7 7 2 2 2 6 6 6 1 2 2 0 1 0 2 2 2 Figure 77 Configuration files with default data.com The document is for study only.if tort to your rights.we will delete 119 . com EMail:cadserv21@hotmail. Configuration file Logical axis Measuring system System* Node* 1 2 3 4 5 6 System* 2 2 2 2 2 2 Drive system Unit position 0 1 2 3 4 5 Node 1 1 1 1 1 1 EN1M2D2 EN2M2D2 EN3M2D2 EN4M2D2 EN5M2D2 EN6M2D2 8 9 10 11 12 13 2 2 2 2 2 12 Figure 79 Configuration files with default data. Logical axis is used as the axis number in the RAPID instruction and for the teach pendent.we will delete . Incorrect definitions of the system parameters for brakes or external axes may cause damage to the robot or personal injury.cadfamily. Configuration file Logical axis Measuring system System* AC1M1D1 AC2M1D1 AC3M1D1 AC4M1D1 AC5M1D1 AC6M1D1 7 8 9 10 11 12 1 1 1 1 1 1 Node* 1 2 3 4 5 6 System* 1 1 1 1 1 1 Drive system Unit position 1 2 3 2 3 1 Node 2 2 2 1 1 1 Figure 78 Configuration files with default data.com The document is for study only. note the limitation described under drive system. Normally the robot use axes 1-6 and the external axes 7-12. 120 Product Manual IRB 2400 www. The user can change the logical axis number to fit the new application.if tort to your rights. If drive units with three inverters are used.External Axes * Parameter value must not be changed. Only axes with unique axis numbers may be active at the same time.please inform us. Installation and Commissioning ** Is connected physically to node 4 but the logical value in the system parameters must be 7. .. 2............................... 2 Instructions for Maintenance .................................. 2........ axis 1 ..........3 Changing the battery in the measuring system ........................................................................if tort to your rights................. 2.....4 Changing filters/vacuum cleaning the drive-system cooling.........................................................Maintenance CONTENTS Page 1 Maintenance intervals ....6 Changing the battery for memory back-up ..................please inform us................................................................ 2....................... 3 4 4 4 4 6 6 6 8 www...............................2 Signal cabling upper arm ...............1 Oil in gears ..............................com Product Manual IRB 2400 The document is for study only.................................cadfamily.....................................................................com EMail:[email protected] will delete 1 . 2.7 RAM Battery lifetime . 2.......................................5 Checking the mechanical stop................ 2......................... please inform us.com 2 Product Manual IRB 2400 The document is for study only.we will delete .Maintenance CONTENTS Page www.cadfamily.if tort to your rights.com EMail:cadserv21@hotmail. Is only needed if the robot is working in an enviroment temperature over 40o C. In very dusty environments. 2. bearings. Change for the first time after 1 year or 4000 hours. 1 Maintenance intervals MANIPULATOR Prescribed maintenance Measuring system Change battery Change the signal cabling upper arm. • The exterior of the robot should be cleaned as required. nevertheless. time in operation 4000 hrs (1 year with two shift) 12 000 hrs (3 years with two shift) Others 3 years1 1. 3. the interior of the cabinet should be inspected at regular intervals. lacquer or cabling must not be used. See section 2. Change filter according to prescribed maintenance. See section 2. if option 04y Mechanical stop axis 1 Wrist unit Change oil CONTROLLER Memory back-up Change battery Filter for drive-system cooling X5 X Have to be changed if bent.please inform us. Nevertheless. www. see the table below.3. • Check that the sealing joint and cable bushings are really airtight so that dust and dirt are not sucked into the cabinet. Change interval strongly dependent on environment around the control system. An extra dust filter for the cooling device is supplied with the robot. • The control system is completely encased which means that the electronics are protected in any normal working environment.6. after that every five years.cadfamily.com Product Manual IRB 2400 The document is for study only. Use a vacuum cleaner if necessary. 5.we will delete 3 . Compressed air and harsh solvents that can damage the sealing joints.if tort to your rights. Use a vacuum cleaner or wipe it with a cloth. certain routine checks and preventative maintenance must be carried out at given periodical intervals.com EMail:[email protected] Maintenance The robot is designed to be able to work under very demanding circumstances with a minimum of maintenance. 4. X2 X3 5 years 5 years4 Check twice a year Maintenance intervals. (This means that it will not have to be coarse-calibrated after the battery change.cadfamily. • Install a new battery with a clasp and connect the terminals to the serial measuring board. section Cabling and Measuring board. 2.if tort to your rights. • Set the robot to the MOTORS OFF operating mode. 2. 3 and 4 are lubricated for life with oil. The cabling is changed as described in the chapter Repairs. The battery must never be just thrown away. 2.we will delete .com EMail:cadserv21@hotmail. www.com 4 Product Manual IRB 2400 The document is for study only.please inform us.3 Changing the battery in the measuring system The battery to be replaced is located in the base (see Figure 1). Oil in gearboxes 5 and 6 must be changed at the intervals specified in the maintenance table.) • Loosen the battery terminals from the serial measuring board and cut the clasp that keep the battery unit in place.2 Signal cabling upper arm The cabling must be changed at intervals specified in the maintenance table. The robot is delivered with a rechargeable Nickel-Cadmium (Ni-Cd) battery with article number 4944 026-4.1 Oil in gears The gearboxes for axes 1.Maintenance 2 Instructions for Maintenance 2. section Oil change in gearboxes. which corresponds to 40 000 hours in operation. it must always be handled as hazardous waste. The oil is checked and changed as described in the chapter Repairs. art. Vacation (4 weeks) power off 2.we will delete 5 . compare with the Ni-Cd battery’s max life time of 3 years in service.no.com Product Manual IRB 2400 The document is for study only. Voltage of batteries.no. www. Two lithium batteries exists: .com EMail:cadserv21@hotmail. Alternative battery As an alternative to the Ni-Cd battery a lithium battery of primary type can be installed. art. measured at power off: Min Ni-Cd Lithium 7.7 V - Exchange of the battery is done according to the first section of this chapter. which can be up to 5 years in service. 3HAB 9999-1 . 3HAB 9999-2 The life time of the lithium battery depends on how frequently the user switches off the power.Maintenance • The battery takes 36 hours to recharge. The lithium battery needs no charging and has for that reason a blocking diode which prevents charging from the serial measurement board.if tort to your rights. The benefit with a lithium battery is the lifetime. Figure 1 The battery is located in the base.please inform us.0 V 7. Weekend power off + user type 1 3. the mains supply must be switched on during this time and there must not be any power interrupts.cadfamily.a 3-cell battery. 8. Nightly power off + user type 1 and 2 Exchange 3-cell: every 5 years every 2 years every year Exchange 6-cell: every 5 years* every 4 years every 2 years * Because of material ageing the maximum life time in service is 5 years. The estimated max life time in years for the different lithium batteries and the recommended exchange interval is shown below: User type: 1. Remove the cover to get access to the battery.a 6-cell battery.0 V Max. 5 Checking the mechanical stop.Maintenance 2. but should be allowed to dry on a flat surface.com EMail:cadserv21@hotmail. the rough surface (on the clean-air side) should be turned inwards. 2.we will delete . Clean the filter three or four times in 30-40° water with washing-up liquid or detergent. the filter can be blown clean with compressed air from the clean-air side. www. The filter must not be wrung out. the entire cooling duct must be vacuum cleaned regularly. axis 1 Check regularly. • If an air filter is not used.com 6 Product Manual IRB 2400 The document is for study only. If the stop pin is bent.4 Changing filters/vacuum cleaning the drive-system cooling The article number of the filter is 3HAB 8028-1. it must be replaced by a new one.that the pin is not bent. The article number of the pin is 3HAB 6687-1 2. at the top of the rear wall (see Figure 2). Alternatively.6 Changing the battery for memory back-up Type: Lithium Battery. • Remove the old filter and install a new one (or clean the old one and re-install it). The article number of the battery is 3HAB 2038-1 The batteries (two) are located under the top cover to the right. • When cleaning. as follows: Stop pin: .please inform us. • Loosen the filter holder on the outside of the door by moving the holder upwards.if tort to your rights.cadfamily. • Do not incinerate the batteries or expose them to high temperatures. www. causing severe burns. Figure 2 The location of the batteries on the computer unit. see Installation and Commissioning. or destruction of case integrity and the hermetic seal.cadfamily. Warning: Do not incinerate or dispose of lithium batteries in general waste collection. and inflammable liquids. An explosion could result or the cells could overheat. Excessive heat could build up. • Do not connect positive and negative terminals. corrosive.if tort to your rights.we will delete 7 . • Do not open.com Product Manual IRB 2400 The document is for study only. puncture. • Note from the teach pendant which of the two batteries has expired and needs replacement. compacting. crush.com EMail:cadserv21@hotmail. An explosion could result.Maintenance . or otherwise mutilate the batteries. If not all memory content will be erased. This could cause an explosion and/or expose toxic. • Loosen the expired battery terminal from the backplane. • Remove the battery by loosening the clasps. Plan view Front view Warning: • Do not charge the batteries. Batteries should be collected for disposal in a manner that prevents short circuitting.please inform us. • Insert the new battery and fasten the clasps. • If both batteries must be replaced. as there is a risk of explosion. A complete new installation of Robot Ware and parameters is then necessary. Do not attempt to solder batteries. • Connect the battery terminal to the backplane. make sure that the power is on. 7 RAM Battery lifetime The maximum service lifetime of the battery is five years. .3V” i.com 8 Product Manual IRB 2400 The document is for study only. Failing test results in one of the following messages on the display: .31501 Battery voltage too low on battery 1.“Error: Battery 1 and 2 < 3.cadfamily.31503 Battery voltage too low on both batteries. Failing test results in one of the following messages on the display: . www. .please inform us. that memory will be held if the system is without power: Memory board size 4 MB 6 MB 8 MB 16 MB First battery 6 5 6.e.31502 Battery voltage too low on battery 2. . The lifetime is influenced by the installed memory board type and by the length of time the system is without power. Warm start.we will delete .e.5 5 Both batteries 12 10 13 10 A battery test is performed during the following occasions: 1.“Warning: Battery 1 or 2 < 3. 2. both batteries are empty.Maintenance 2.com EMail:cadserv21@hotmail. one of the batteries is empty. The following table indicates the minimum time. System diagnostics (before software installation).3V” i. in months.if tort to your rights. .................................. 35 3...................................... 1... 23 2.................................... 22 2.................................3 Drive system................................. 35 3..............4.. 1.......... 14 2...................................2 Console connected to a PC ..............................................................4........................................................................................................3 Main computer DSQC 361 ........................................................................................ 14 2.................. DSQC 355...............10 Remote I/O DSQC 350.....1 Entering the test mode from the teach pendant ................................................................ 38 3.......7 Panel unit DSQC 331..................if tort to your rights................4........14 Status LEDs description....................4 Memory board DSQC 324/16Mb..................................................................please inform us........................................................4............................................. 17 2....... 14 2... 27 3 Measuring Points ..............................8 Digital and Combi I/O units...............................1 Power supply ............................................... 15 2................... 34 3...............................................................................................4 X9 Maintenance plug ...............................................................................................................................6 Power supply units ................ DSQC354 ......................................................... 34 3............................. 323/8Mb .............4..........................7 CAN....................................................com EMail:cadserv21@hotmail......... 20 2............................. 3 5 6 7 7 2 Indication LEDs on the Various Units ............... 39 3..................................................................................................................................................................................................1 Location of units in the cabinet.................. 30 3............... 25 2............................. 39 www.............. RS 232 and RS 422 .......................6 Teach pendant....... 21 2.......................................... 16 2...................2 X9 VBATT 1 and 2 .1 Back plane......4.. 33 3......................11 Interbus-S................................................................. 36 3..3 X1 and X2 Serial links: SIO 1 and SIO 2 ............................................................................................................................................................we will delete 1 ....... 1...............................2 Monitor Mode 2 .................................5 Disk drive .........................................4 Measuring system........13 Encoder interface unit................. 37 3..............4....................com Product Manual The document is for study only.... DSQC352 .................................1 Tests ..2......12 Profibus-DP... Allen Bradley...... 19 2...........................2.... 24 2..................... 31 3....... slave DSQC 351 .....9 Analog I/O............................................................................................................... 30 3............. 1..............................................Troubleshooting Tools CONTENTS Page 1 Diagnostics...5 Ethernet DSQC 336 .......................................... 15 2............................4.......................2 Robot computer DSQC 363/373 .............................................cadfamily.......................................2 Signal description...8 Safety.. com 2 Product Manual The document is for study only.com EMail:[email protected] inform us.cadfamily.Troubleshooting Tools CONTENTS Page www.if tort to your rights.we will delete . the test programs are executed by the robot computer (I/O computer) and the main computer. This enables an “error audit trail” to be made which can be analysed. only a subset of the test program is executed. INIT.if tort to your rights. These tests and the test results are displayed on the teach pendant. etc.. During a warm start. www. What these messages mean is described in System and Error Messages. • Switch the power off and then on. Any errors detected by the diagnostics are displayed in plain language with an code number on the display of the teach pendant. requesting you to insert a system diskette into the disk drive. If the tests do not indicate any errors. Another type of warm start. Warm Start is the normal type of start up when the robot is powered on. • Check the LEDs on the units. The tests performed during the self diagnostic are described in the chapter Diagnostics page 3. These tests and the test results are displayed on the teach pendant. See Indication LEDs on the Various Units page 14. or when any computer board has been replaced. a self diagnostic is run which detects any errors. a message will appear on the display and the test will be stopped until the user hits a key on the teach pendant or on a terminal connected to the front connector on the robot computer. The tests that are run depend on whether or not the system is booted. however. First. When the robot is started up. the diagnostics detect an error. If. All system and error messages are logged in a common log which contains the last 50 messages saved. troubleshooting should be carried out as follows: • Read any error messages shown on the teach pendant display.please inform us.Troubleshooting Tools Troubleshooting Tools Generally speaking. 1 Diagnostics The control system is supplied with diagnostic software to facilitate troubleshooting and to reduce downtime. a message will appear on the display. or when the batteries have been disconnected.com EMail:cadserv21@hotmail. with the help of the circuit diagram.we will delete 3 . • Check the cables.cadfamily. The diagnostic programs are executed by the I/O computer. is carried out via a push button located on the backplane (see section 3). The log can be accessed from the Service window using the teach pendant during normal operation and can be used to read or delete the logs. The control system runs through various tests depending on the start up mode: Cold Start Cold starts occur normally only when the control system is started the first time. All system and error messages available are listed in User’s Guide. INIT is very similar to switching the power on.com Product Manual The document is for study only. The diagnostic programs are stored in flash PROM on the robot computer board. 2. Under normal operating conditions. A detailed description will be found in Chapter 1. The operating system ensures that the tests can be run whenever there is a time slot. but will give an indication when an error occurs. Flow Chart of Diagnostic Software = PROM memory code Power on INIT RESET Warm or cold start? Warm Cold Cold start Rudimentary Run PROM tests Warm Warm start Rudimentary System boot Set start up mode Warm Release system I/O COMPUTER Start up mode Warm System in operation Set flag for warm start MAIN COMPUTER Operating mode Service mode Reset www.cadfamily.com EMail:[email protected] inform us.Troubleshooting Tools Monitor Mode 2 is a test condition in which a large number of tests can be run.we will delete . a number of test programs are run in the background.com 4 Product Manual The document is for study only.if tort to your rights. The background tests are not seen in normal circumstances. . checksum tests.com Product Manual The document is for study only. # T1504: IOC Red LED off # T1005: IOC Memory test (RWM) Non Destructive # T1018: IOC Battery test # T1053: IOC IOC->AXC Access test # T1062: IOC IOC->AXC AM test # T1067: IOC IOC->AXC Memory test (RWM) # T1068: IOC IOC->AXC Memory test (RWM) R6 Global # T1069: IOC IOC->AXC Memory test (RWM) DSP # T1070: IOC Enable AXC->IOC Interrupts # T1061: IOC IOC->AXC Load AXC # T3001: AXC RWM test Dist.please inform us. If it fails. are only run when the robot is warm started. IOC = Robot computer AXC = Robot computer MC = Main computer At every “power on”. etc.2. All the tests can be run in Monitor Mode 2. Cold start tests in consecutive order.if tort to your rights.Troubleshooting Tools 1. as described in Chapter 1.1 Tests Most of the internal robot tests are only run when the robot is cold started.cadfamily.com EMail:cadserv21@hotmail. Non destructive memory tests.we will delete 5 . # T3002: AXC R6 Global RWM test # T3003: AXC DSP Double access RWM test # T3004: AXC DSP Data RWM test # T3020: AXC VME interrupt test # T3023: AXC Test channels output test # T1071: IOC Disable AXC->IOC Interrupts # T1046: IOC IOC->MC Access test # T1048: IOC IOC->MC AM test www. the IOC will flash the NS and MS front LEDs and stop the program running. the IOC makes a destructive RWM test. the IOC will flash the NS and MS front LEDs and stop the program running. To ensure that all memory addresses are resetted after testing shall the system be cold started. accidents etc. www.please inform us. The test mode Monitor mode 2 can be run from the teach pendant and/or a connected PC/terminal. IOC = Robot computer At every “power on”. the IOC makes a destructive RWM test. It should be noted that some of the tests will cause activity on customer connections and drive systems.we will delete . unless suitable precautionary measures are taken. which can result in damage. These tests must be performed only by authorised service personnel.com EMail:cadserv21@hotmail. If it fails.Troubleshooting Tools # T1050: IOC IOC->MC Memory test Destructive. Low win # T1506: IOC IOC->MC LED off # T1508: IOC IOC->ERWM LED off # T1512: IOC IOC->MC Load MC # T1509: IOC IOC->MC Release MC # T2002: MC Memory test (RWM) Destructive # T2010: MC Memory test (RWM) BM Destructive # T1510: IOC IOC->MC Reset MC Warm start tests in consecutive order.cadfamily.2 Monitor Mode 2 When the system is in Monitor Mode 2.com 6 Product Manual The document is for study only. It is advisable to disconnect all the connections involved during these tests.if tort to your rights. a large number of tests can be run. # T1504: IOC LED off # T1005: IOC Memory test (RWM) Non Destructive # T1018: IOC Battery test 1. com Product Manual The document is for study only. Entering the test mode from a PC/terminal: 1.2.cadfamily. Connect the PC.Troubleshooting Tools 1.2 Console connected to a PC A PC with terminal emulation (see PC manual). Turn on the power to the robot. Push the INIT button. Press the backplane TEST button.1 Entering the test mode from the teach pendant 1.please inform us. see section 3 (keep the TEST button pressed in).com EMail:cadserv21@hotmail. (after releasing of the INIT button). 4. (after release of the INIT button). Keep the TEST button depressed for at least 5 sec. Keep the TEST button depressed for at least 5 sec. 1. Press the backplane TEST button. see section 3 (keep the TEST button pressed in). Then enter the password: 4433221. 2. 2. no parity. 5. Connection table: Console terminal on robot and main computer Console Pin 2 3 5 Signal RXD TXD GND Description Serial receive data Serial transmit data Signal ground (0V) Start up: 1. 8 bits. see section 3. 2.we will delete 7 . see section 3. Keep the button depressed. The display will show the following: MONITOR MODE 2 if you proceed. system data will be lost! Press any key to accept.2.if tort to your rights. 3. 4. 3. and shall be connected to the Console terminal on the front of the robot computer board. 5. Keep the button depressed. The PC shall be set up for 9600 baud. The display will show the following: www. Push the INIT button. 6. com 8 Product Manual The document is for study only. T1068 IOC->AXC Memory test (RWM) R6 Global 4. T1039 IOC Floppy Format Test 3. T1067 IOC->AXC Memory test (RWM) 3.cadfamily. a menu will be displayed. Auxiliary 9. DSQC 3xx (IOC) 5. T3001 AXC RWM test Destr 6. FLOPPY 1. T3003 AXC DSP Double access RWM test 8. 6. system data will be lost! Press any key on the PC to accept. System tests (MISC) 8.com EMail:cadserv21@hotmail. DSQC 3xx (AXC) 6. AXC RWM 1. When the password has been entered (see above). T1516 TIOC RWM size 3. T1040 IOC Floppy Write/Read Test 3. T3002 AXC R6 Global RWM test 7. T9901 Memory IO 1. Serial IO 3. DSQC 3xx (MC. 1.if tort to your rights. Up one level 2. T1060 IOC System reset Select test group and the test group menu will be displayed.please inform us. T1069 IOC->AXC Memory test (RWM) DSP 5.Troubleshooting Tools MONITOR MODE 2 if you proceed. Up one level 2. Specific test 10. IOC RWM 1. Up one level 2. Then enter the password: ROBSERV. Elementary IO 4. T1005 IOC Memory test (RWM) Non destructive 4. as shown below: Welcome to Monitor Mode 2 1. Memory IO 2. T3004 AXC DSP Data RWM test (Tests the memory) (Tests the serial channels) (Tests the IO units) Not yet implemented (Tests the IO computer) (Tests the axes computer) (Tests the main computer and external memory boards) (System-related tests) (Special tests) Not yet implemented (Specific tests that can be run separately) www. ERWM) 7.we will delete . Up one level 2. TPUNIT (Not yet implemented) 3. T1516 IOC RWM size 3. PROM (Not yet implemented) 4. T1040 IOC Floppy Write/Read Test www. SIO 1 (Not yet implemented) 3.please inform us. T9800 Up one level 2. T1005 IOC Memory test (RWM) Non Destructive 5. Up one level 2. Up one level 2. Up one level 2. T1047 IOC IOC->MC Memory test Destructive 4. T9911 DSQC 3xx (IOC) 1. CONSOLE (Not yet implemented) 5.com Product Manual The document is for study only. MC/ERWM RWM 1. T1517 MC/ERWM RWM size 3. Up one level 2.we will delete 9 .cadfamily.if tort to your rights. IOC CPU (Not yet implemented) 3. T1029 IOC SIO2 RS422 loopback test 3.Troubleshooting Tools 5. PROM (Not yet implemented) 2.com EMail:cadserv21@hotmail. RTC (Not yet implemented) 6. T9903 Elementary I/O (Not yet implemented) 4. Up one level 2. T9902 Serial I/O 1. RWM 1. T2002 MC Memory test (RWM) Destructive 5. T1039 IOC Floppy Format Test 3. FDC 1. T1033 IOC SIO2 RS422 JUMPER test (Requires special hardware jumpers) 4. T2010 MC Memory test (RWM) BM Destructive 6. SIO 2 1. T1053 IOC IOC->AXC Access test 3. Miscellaneous 1. Up one level 2. T1033 IOC SIO2 RS422 JUMPER test (requires special hardware jumpers) 5. LED 1.if tort to your rights. AXC CPU (Not yet implemented) 3. T9800 Up one level 2. T1029 IOC SIO2 RS422 loopback test 3. T3003 AXC DSP Double access RWM test 8. T1069 IOC IOC->AXC Memory test (RWM) DSP 5. Up one level 2. T9800 Up one level 2.please inform us. T1503 IOC LED on 3. RWM 1. T3002 AXC R6 Global RWM test 7.cadfamily. T1518 IOC CAN LEDs sequence test 5. T1060 IOC System Reset 11. T1067 IOC IOC->AXC Memory test (RWM) 3.com EMail:cadserv21@hotmail. VME 1. Up one level 2. T3004 AXC DSP Data RWM test 4.Troubleshooting Tools 7. DSQC 3xx (AXC) 1. T3020 AXC VME interrupt test www. T3001 AXC RWM test Dstr 6.we will delete . DMA (Not yet implemented) 9. T1022 IOC TPUNIT RS422 JUMPER test (Requires special hardware jumpers and must be run from terminal) 8. T1013 IOC TPUNIT RS422 loopback test 4. Up one level 2. VME (Not yet implemented) 10. T1068 IOC IOC->AXC Memory test (RWM) R6 Global 4.com 10 Product Manual The document is for study only. T1018 IOC Battery test startup 3. T1062 IOC IOC->AXC AM test 4. UART 1. T1504 IOC LED off 4. RWM 1. T3019 AXC Board ID number 7. T2010 MC Memory test (RWM) BM Destructive 4. Up one level 2.we will delete 11 . LED 1. T1046 IOC IOC->MC Access test 7.if tort to your rights. Up one level 2. ERWM) 1. T1508 IOC IOC->ERWM LED off 6. Up one level 2. T1048 IOC IOC->MC AM test 3. Miscellaneous 1. T1071 IOC Enable AXC->IOC Interrupts 4. Duart (Not yet implemented) 6. Miscellanous 1. T1512 LOAD MC DIAG 3. Up one level 2. T2002 MC Memory test (RWM) Destructive 5. T2502 MC LED off 5.cadfamily.Troubleshooting Tools 5. DSQC 3xx (MC. T2501 MC LED on 7. T1505 IOC IOC->MC LED on 3. Up one level 2. T1061 IOC IOC->AXC Load AXC 5. T1517 MC/ERWM RWM size 3. T1071 IOC Disable AXC->IOC Interrupts 6.com Product Manual The document is for study only. DMA (Not yet implemented) 8. T3023 AXC Test channels output test 8. T1510 DISABLE (RESET) MC www. MC CPU (Not yet implemented) 3. T1072 IOC IOC->AXC Reset AXC 3. T1047 IOC IOC->MC Memory test Destructive 4.please inform us. T3018 AXC ASIC ID number 6. T1509 ENABLE MC 4. T1507 IOC IOC->ERWM LED on 5.com EMail:cadserv21@hotmail. T1506 IOC IOC->MC LED off 4. VME 1. Up one level 2. T1512 LOAD MC DIAG 9. Battery 1. MC->AXC (Not yet implemented) 6.) 1. Cold start (Not yet implemented) 8. IOC->MC 1.please inform us. T2502 MC LED off 4. T1506 IOC IOC->MC LED off 6. IOC->AXC 1.cadfamily.Troubleshooting Tools 7.if tort to your rights. T1071 IOC Disable AXC->IOC Interrupts 5. T9800 Up one level 2. T1507 IOC IOC->ERWM LED on 7. Up one level 2. T1505 IOC IOC->MC LED on 5.com EMail:cadserv21@hotmail. T3020 AXC VME interrupt test 10. T1053 IOC IOC->AXC Access test 4. T1048 IOC IOC->MC AM test 4. AXC->IOC (Not yet implemented) 7. T1070 IOC Enable AXC->IOC Interrupts 6.we will delete . T3023 AXC Test channels output test 11. RTC (Not yet implemented) 9. T3019 AXC Board ID number 9. Auxiliary (Not yet implemented) www. T1046 IOC IOC->MC Access test 3. VME (Not yet implemented) 8. T1508 IOC IOC->ERWM LED off 8.com 12 Product Manual The document is for study only. System tests (Misc. T1018 IOC Battery test startup 3. T3018 AXC ASIC ID number 8. Reset password (Re-boot required) 10. T1061 IOC IOC->AXC Load AXC 7. Up one level 2. T1062 IOC IOC->AXC AM test 3. Up one level 2. T1072 IOC IOC->AXC Reset AXC 5. T2501 MC LED on 12. T1510 DISABLE (RESET) MC 11. T1509 ENABLE MC 10. we will delete 13 .cadfamily. www.if tort to your rights.com Product Manual The document is for study only. IOC System reset (Not yet implemented) All available tests have been defined in Chapter 1. Specific test Specific test Txxxx <Q> <q> or < > to quit Enter test number Txxxx: T 10.Troubleshooting Tools 9.com EMail:[email protected] inform us.1. 14.com 14 Product Manual The document is for study only. See section 2. 6(C) 2(Y). 1 (4). 6 2.we will delete Optional board Memory board . SIO2 TxD RxD CAN NS MS DSQC 322 MS F C O N S O L E www.Troubleshooting Tools 2 Indication LEDs on the Various Units 2.cadfamily. 4 3. 5 IRB 6400 Axes 1. 6 2. 3 2. See section 2. 3(Z) IRB 340 Axes 2. 6 IRB 2400 Axes 1. 5 IRB 640 Axes 1.14. 2. 4 3.14. 2.com EMail:cadserv21@hotmail. 6 2. 3 IRB 840/A Axes 1(X). 4 3. 4 3.14. See section 2.2 Robot computer DSQC 363/373 SIO1 TxD RxD Designation F TxD RxD NS Colour Red Yellow Yellow Green/red Green/red Description/Remedy Turns off when the board approves the initialisation. 5.please inform us. 6 IRB 4400 Axes 1. 5.1 Location of units in the cabinet Drive unit 3 Drive unit 2 Drive unit 1 DC link Robot computer Main computer Optional board Supply unit Transformer IRB 1400 Drive unit 1 2 3 Axes 1.if tort to your rights. See section 2. DSQC 3xx F www.if tort to your rights. DSQC 361 F 2.com Product Manual The document is for study only.4 Memory board DSQC 324/16Mb.cadfamily.3 Main computer DSQC 361 Designation F Colour Red Description/Remedy Turns off when the board approves the initialisation.we will delete 15 .com EMail:[email protected] Tools 2. 323/8Mb Designation F Colour Red Description/Remedy Turns off when the board approves the initialisation.please inform us. check message. By light and message on display.com 16 Product Manual The document is for study only. Light without message on display indicates a hardware fault preventing system from strating.please inform us. check network and connections.if tort to your rights.5 Ethernet DSQC 336 Designation TxD LAN TXD RXD Colour Yellow Description/Remedy Indicates data transmit activity. Lit after reset. If no light. See section 2.com EMail:[email protected] Tools 2. See section 2. Thereafter controlled by the CPU. check error messages and check also system boards in rack. RxD CAN NS MS A U I Yellow NS MS F Green/red Green/red Red DSQC 336 F T P E C O N S O L E www.14.we will delete .cadfamily. Indicates data receive activity.14. If no light when transmission is expected. please inform us.com Product Manual The document is for study only.we will delete 17 .com EMail:[email protected] Tools 2. introduced week 826 (M98 rev. 1) New “extended” power supply unit DSQC 365 introduced week 840.if tort to your rights.6 Power supply units DSQC 334 X1 X5 AC OK X2 X3 Designation AC OK Colour Green Description/Remedy 3 x 55V supply OK (start of ENABLE chain) DSQC 374/365 New “standard” power supply unit DSQC 374.cadfamily. www. please inform us.Troubleshooting Tools X1 X3 X5 AC OK 24 V I/O X2 X7 Only DSQC 365 Designation AC OK 24 V I/O Colour Green Green Description/Remedy 3 x 55V supply OK (start of ENABLE chain) 24 V I/O OK www.com 18 Product Manual The document is for study only.cadfamily.if tort to your rights.we will delete .com EMail:cadserv21@hotmail. we will delete 19 .please inform us.Troubleshooting Tools 2.if tort to your rights. Emergency stop chain 1 and 2 closed General stop switch chain 1 and 2 closed Auto stop switch chain 1 and 2 closed www.cadfamily.14.com Product Manual The document is for study only.com EMail:[email protected] Panel unit DSQC 331 WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT EN Status LED’s MS NS ES1 ES2 GS1 GS2 AS1 AS2 Designation EN MS/NS ES1 and 2 GS1 and 2 AS1 and 2 Colour Green Green/red Yellow Yellow Yellow Description/Remedy Enable signal from power supply and computers See section 2. please inform us. The higher the applied voltage.com 20 Product Manual The document is for study only. The description below is applicable for the following I/O units: Digital I/O DSQC 328. Status LED’s 1 2 3 4 5 6 7 8 OUT IN MS NS X2 OUT 9 10 11 12 13 14 15 16 IN X1 1 10 1 X4 10 1 X3 10 1 10 12 1 X5 Designation IN Colour Yellow Description/Remedy Lights at high signal on an input.Troubleshooting Tools 2. the brighter the LED will shine. OUT Yellow MS/NS Green/red www. DSQC 328.cadfamily. Lights at high signal on an output.if tort to your rights. The higher the applied voltage.com EMail:cadserv21@hotmail. the brighter the LED will shine. Combi I/O DSQC 327. See section 2.8 Digital and Combi I/O units All the I/O units have the same LED indications.14. the LED will glow dimly. This means that even if the input voltage is just under the voltage level “1”. Relay I/O DSQC 332 and 120 VAC I/O DSQC 320. The figure below shows a digital I/O unit.we will delete . LED is active when tranceiving data. If no light when transmission is expected.if tort to your rights.com Product Manual The document is for study only. check cables and connectors.U RS232 Rx CAN Rx +5V +12V MS N. LED is active when receiving data.please inform us. Indicates the state of the RS232 Tx line.com EMail:[email protected] RS232 Tx CAN Tx -12V NS Analog I/O DSQC 355 ABB flexible Automation Designation NS/MS RS232 Rx Colour Green/red Green Description/Remedy See section 2.9 Analog I/O.Troubleshooting Tools 2. check communication line and connections. If no light. Check that power is present in power connector. Check that voltage is present on power unit.we will delete 21 . www.14.cadfamily. DSQC 355 Bus status LED’s Bus staus LED’s X8 S2 S3 X2 X5 X3 X7 N. replace the unit. RS232 Tx Green +5VDC / +12VDC / -12VDC Green Indicates that supply voltage is present and at correct level. Indicates the state of the RS232 Rx line. If not. check error messages and check also system boards in rack. If power is applied to unit but unit does not work. cables and connections.cadfamily. or configuration or rack size etc. That power is present in power connector. See section 2.14. Allen Bradley Bus status LED’s POWER NS MS CAN Tx CAN Rx NAC STATUS X5 X9 POWER NS MS CAN Tx CAN Rx NAC STATUS X3 X8 DSQC 350 ABB Flexible Atomation Designation POWER-24 VDC Colour Green Description/Remedy Indicates that a supply voltage is present. If power is applied to unit but unit does not work. not matching configuration set in PLC.we will delete .10 Remote I/O DSQC 350. Check that PLC is operational.com EMail:cadserv21@hotmail. and has a level above 12 VDC. If LED keeps flashing continuously.com 22 Product Manual The document is for study only.if tort to your rights. Steady green indicates RIO link in operation.14. If not. communication established. Flashing green. If no light. check network. replace unit. check that voltage is present on power unit. but INIT_COMPLETE bit not set in NA chip. check cables and connectors. If no light. See section 2.please inform us. check setup NS/MS NAC STATUS Green/red Green CAN Tx/CAN Rx Yellow www.Troubleshooting Tools 2. 11 Interbus-S. nodes and connections Lit when Interbus-S communication runs without errors. check parameter setup. If no light. Green Red Lit when both 5 VDC supplies are within limits.14.if tort to your rights.Troubleshooting Tools 2. BA Green RC Green www.14. slave DSQC 351 Bus status LED’s X20 RC BA RBDA POWER X21 ABB Flexible Automation POWER NS MS CAN Tx CAN Rx X5 X3 DSQC 351 Interbus-S CAN Rx CAN Tx MS NS POWER POWER RBDA BA RC Designation POWER-24 VDC NS/MS CAN Tx/CAN Rx POWER.we will delete 23 .5 VDC RBDA Colour Green Description/Remedy Indicates that a supply voltage is present. Lit when Interbus-S is active. and no reset is active. Green/red See section 2.com Product Manual The document is for study only.cadfamily. and has a level above 12 VDC. Lit when this Interbus-S station is last in the Interbus-S network. Green/red See section 2.com EMail:cadserv21@hotmail. check network. If not as required.please inform us. Green/red See section 2.com EMail:[email protected]. Green Indicates that a supply voltage is present. and has a level above 12 VDC.com 24 Product Manual The document is for study only.Troubleshooting Tools 2.14.we will delete . DSQC352 X20 ABB Flexible Automation Bus status LED’s Profibus active NS MS CAN Tx CAN Rx Power PROFIBUS ACTIVE X5 X3 Designation Profibus active with DSQC 352 Profibus NS MS CAN Tx CAN Rx POWER Colour Green Description/Remedy Lit when the node is communicating the master. check cables and connectors.cadfamily. replace the unit www. If not. If power is available at the unit but the unit does not function.please inform us.if tort to your rights.Check that power is present in the power connector.12 Profibus-DP. check that voltage is present in power unit. check system messages in robot and in Profibus net. 24 VDC Green/red See section 2. NS/MS CAN Tx/CAN Rx POWER. If no light. If no light. flashing can no longer be observed (light will appear weaker). If not.Troubleshooting Tools 2. That power is present in connector X20. See section 2.if tort to your rights. No light in one LED indicates fault in one encoder phase.14. External wiring or connectors. faulty power supply for input circuit (internal or external). See section 2. Constant light indi cates constant high level on input and vice versa. Indicates phase 1 and 2 from encoder. NS/MS CAN Tx/CAN Rx ENC 1A/1B Green/red Yellow Green www. 24 VDC Colour Green Description/Remedy Indicates that a supply voltage is present.com EMail:cadserv21@hotmail. check cables and connectors.we will delete 25 . and has a level above 12 VDC. DSQC354 Status LED’s ABB Flexible Automation X20 Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A POWER NS MS CAN Tx CAN Rx ENC 1A ENC 1B DIGIN 1 X5 X3 DSQC 354 Encoder CAN Rx CAN Tx MS NS POWER Designation POWER.14. Defective input circuit on board. If no light. If no light. By frequencies higher than a few Hz.please inform us. Internal error in unit.If power is applied to unit but unit does not work. check that voltage is present on power unit.com Product Manual The document is for study only. replace unit.13 Encoder interface unit. short circuit or broken wire.cadfamily. Flashes by each Encoder pulse. www. The input is used for external start signal/conveyor synchronization point. External wiring or connectors. faulty limit switch.please inform us.com EMail:cadserv21@hotmail. photocell etc. Faulty power supply for input circuit (internal or external). short circuit or broken wire.we will delete .cadfamily.Troubleshooting Tools DIGIN1 Green Digital input.if tort to your rights. If no light. Defective input circuit on board.com 26 Product Manual The document is for study only. Lit when digital input is active. CAN network transmit CAN Rx . If flashing for more than a few seconds. Flashing red/green The device is running self test.cadfamily. Red The device has an unrecoverable fault.Module status This bicolour (green/red) LED provides device status. Flashing green Device needs commissioning due to configuration missing.we will delete 27 . Remedy / Source of fault Check power supply.com Product Manual The document is for study only.14 Status LEDs description Each of the units connected to the CAN bus includes 2 or 4 LED indicators which indicate the condition (health) of the unit and the function of the network communication. Device may need replacing. incomplete or incorrect. The table below shows the different states of the MS LED.CAN network receive MS . The device may be in the Stand-by state. Flashing red Recoverable minor fault. www. check other LED modes.Network status Some units: CAN Tx . Green If no light. These LEDs are: All units MS .com EMail:cadserv21@hotmail. check hardware. Check messages. Description Off No power applied to the device. Check system parameters. Check messages.Module status NS . It indicates whether or not the device has power and is operating properly.please inform us.if tort to your rights. Device is operating in a normal condition.Troubleshooting Tools 2. The LED is controlled by software. Check system messages and parameters. Description Off Device has no power or is not on-line. Check system messages. is on-line. Red Failed communication device. The LED is controlled by software. The device has detected an error that has rendered it incapable of communicating on the network. Check power to affected module.we will delete . For a group 2 only device it means that the device is allocated to a master. Flashing red One or more I/O connections are in the Time-Out state. For a group 2 only device it means that the device is not allocated to a master. Green The device is on-line and has connection in the established state. Flashing green Device is on-line.cadfamily.com 28 Product Manual The document is for study only.com EMail:[email protected] inform us. If no light.Network status The bicolour (green/red) LED indicates the status of the communication link. (Duplicate MAC_ID. but has no established connections to other nodes. The device has passed the Dup_MAC_ID test. For a UCMM capable device it means that the device has no established connections. Check that other nodes in network are operative. check other LED modes. For a UCMM capable device it means that the device has one or more established connections. or Bus-off). but has no connections in the established state. www.Troubleshooting Tools NS . Check parameter to see if module has correct ID. Remedy / Source of fault Check status of MS LED.if tort to your rights. The device has not completed the Dup_MAC_ID test yet. The table below shows the different states of the NS LED. MS LED is switched On green for approx. 0. Flashes when the CPU is transmitting data on the Can bus.. CAN Rx .cadfamily. . check error messages. www. 0.we will delete 29 . Flashes when the CPU is receiving data on the CAN bus. .CAN network transmit Description Green LED.MS LED is switched On green. The purpose of this test is to check that all LEDs are functioning properly. 0... Physically connected to the Can Tx line.NS LED is switched Off.if tort to your rights. Physically connected to the Can Rx line.CAN network receive Description Green LED. 0.MS LED is switched On red for approx.com Product Manual The document is for study only.25 seconds.25 seconds. The test runs as follows: . Remedy / Source of fault If no light when transmission is expected.25 seconds..NS LED is switched On red for approx.and network status LEDs at power-up The system performs a test of the MS and NS LEDs during start-up.please inform us. . Remedy / Source of fault If no light.. each LED is tested in sequence.25 seconds.NS LED is switched On red.com EMail:cadserv21@hotmail. . . Check system boards in rack. check network and connections. CAN Tx .NS LED is switched On green for approx.. .. If a device has other LEDs.Troubleshooting Tools Module. data .com 30 Product Manual The document is for study only.if tort to your rights.please inform us. board 1. X12 (ext. axes) Accessible from cabinet top CAN3 (ext.Troubleshooting Tools 3 Measuring Points 3.1 Back plane The backplane contains a maintenance plug (X9) for signals that are hard to reach.cadfamily. which can come in very handy when troubleshooting (see Figure 1). axes) Serial meas. X22 (manipulator) Accessible by cabinet door Serial meas. X14 (ext. Serial ports SIO 1 RS 232 SIO2 RS 422 Battery 1 2 Test points X5-X8 Maintenance plug. X23 (manipulator) Power contact can also be a 15-pole contact. X9 Drive units. Other signals are measured at their respective connection points. SIO1 and SIO 2 can also be D-sub contacts. I/O) CAN2 (manip. both variant will exsist Power supply Figure 1 Back plane www. alt.supply S1 = INIT button S2 = TEST button Drive units. both variants will exist. I/O) CAN1 (panel unit) Disk drive .we will delete .com EMail:cadserv21@hotmail. board 2. com Product Manual The document is for study only. The transmission pattern can be single or bursts of 10 bit words.cadfamily. www.2 Signal description.if tort to your rights.please inform us. RS 232 and RS 422 RS 232 Signal TXD RXD DSR DTR CTS RTS Explanation Transmit Data Receive Data Data Set Ready Data Terminal Ready Clear To Send Request To Send Stop bit (“1”) Start bit (“0”) 10 V 0V Byte 1 Byte 2 f=9600/19200 baud Figure 2 Signal description for RS 232.com EMail:[email protected] will delete 31 .Troubleshooting Tools 3. with one start bit “0”. eight data bits (MSB first) and lastly one stop bit “1”. it is likely that one or several line(s) or one or several drive circuit(s) is/are faulty.if tort to your rights.Troubleshooting Tools RS 422 Signal TXD4/TXD4 N RXD4/RXD4 N DATA4/DATA4 N DCLK4/DCLK4 N Explanation Transmit Data in Full Duplex Mode Receive Data in Full Duplex Mode Data Signals in Half Duplex Mode Data Transmission Clock N. If the types of signal as shown in the above diagram are obtained when measuring. The data transmission has the same structure as RS 232.please inform us.com EMail:cadserv21@hotmail. By looking at the “true” channel.e. this means that the drive circuits and lines are OK. Signal XXX 5V 5V Signal XXX N f= 9600 38400 baud Figure 3 Signal description for RS 422. When measuring the differential RS 422 signals. differential transmission. it is possible to read the data. 1 start bit + 8 data bits + 1 stop bit.B! Only full duplex is supported. i.cadfamily.com 32 Product Manual The document is for study only. but the signals are differential. If one or both of the signals do not move. www.we will delete . the oscilloscope should be set for AC testing. 2.cadfamily.com EMail:[email protected] tort to your rights. Screw terminals X1 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Signal TXD RTS N 0V RXD CTS N 0V DTR DSR 0V X2 Pin 1 2 3 4 5 6 7 8 9 10 11 12 Signal TXD TXD N 0V RXD RXD N 0V DATA DATA N 0V DCLK DCLK N 0V www.Troubleshooting Tools 3.we will delete 33 .3 X1 and X2 Serial links: SIO 1 and SIO 2 General serial interfaces: SIO 1 (X1) is an RS232 interface and SIO 2 (X2) is an RS422 interface.please inform us. Explanation of signals see 3.com Product Manual The document is for study only. High (= 5V) when power is OK.cadfamily. www.if tort to your rights. ACOK: Follows the AC power input without delay.com 34 Product Manual The document is for study only.1 Power supply Supply voltages can be measured at the following points: X9 Pin 28 29 30 31 32 Row A ACOK + 5V_TST + 15V_TST 15V_TST + 24V_TST Row C DCOK 0V 0V 0V 0V There is a 10 kΩ resistor between each power supply line and the test terminal to prevent damage by a short circuit.4 X9 Maintenance plug 3.4.com EMail:cadserv21@hotmail. DCOK: Follows the supply unit energy buffer.we will delete . After power on. DCOK goes high (=5 V) when output voltages are stable.Troubleshooting Tools D-sub connector X1 Pin 1 2 3 4 5 6 7 8 9 RXD TXD DTR 0V DSR RTS N CTS N Signal X2 Pin 1 2 3 4 5 6 7 8 9 Signal TXD TXD N RXD RXD N 0V DATA DATA N DCLK DCLK N 3.please inform us. please inform us.cadfamily.com Product Manual The document is for study only. DRCI1/DRCO1 signals are connected to the internal drive system (backplane connector X22.2 X9 VBATT 1 and 2 Battery back-up for the computer memory and the real time clock.9 V.we will delete 35 .3 Drive system The signal interface with the drive system. www. X9 Pin 7 8 Row A VBATT1 0V Row C VBATT2 0V 3.if tort to your rights. see 3. It complies with the EIA RS 422 standard.com EMail:[email protected] (Figure 3).Troubleshooting Tools 3. the voltage must be between 3. The DRCI signals enter the robot computer from the drive units.4.1).3 V and 3. X9 Pin 16 17 18 19 20 A DRCI1 DRCO1 DRCI2 DRCO2 0V C DRCI1 N DRCO1 N DRCI2 N DRCO2 N The DRCO signals travel from the robot computer to the drive units. see 3. Voltage of batteries 1 and 2. See 3.1). which means that signal transmission is differential. DRCI2/DRCO2 are connected to external placed drive units (backplane connector X14. MRCI2/MRCO2 are used for external axes (backplane connector X12. It complies with the EIA RS 422 standard. see 3.please inform us.4 Measuring system The signal interface with the serial measuring system.1).4. see 3. X9 Pin 20 21 22 23 24 MRCI1 MRCO1 MRCI2 MRCO2 A C 0V MRCI1 N MRCO1 N MRCI2 N MRCO2 N The MRCO signals travel from the robot computer to the measuring boards.com EMail:[email protected] Tools 3.com 36 Product Manual The document is for study only.if tort to your rights. MRCI1/MRCO1 signals are connected to the IRB axes (backplane connector X23. The MRCI signals enter the robot computer from the measuring boards.cadfamily. see 3.2 (Figure 3). www.we will delete . which means that signal transmission is differential.1). if tort to your rights. “1” <=> +5V. every 200 milliseconds.cadfamily. Indicates whether or not the diskette is write protected. pulses. static active low. Indicates that the heads are to move inwards. One pulse per cycle. pulses. static active low. Starts the motor in the selected unit. static low. Steps the heads in the direction indicated by DIRC N. Write Data. Disk Change. Track 00.com Product Manual The document is for study only. Direction in. Data pulses when writing to the diskette. static active low. X9 Pin 9 10 11 12 13 14 15 A RD N WP N DSKCHG N WD N SSO N DIRC N 0V Explanation Read Data. Indicates which side of the diskette is active.com EMail:[email protected] inform us. c. TTL levels “0” <=> 0V. static active low. pulses.5 Disk drive The signal interface with the disk drive. pulses. Side Select.4. Write Gate. static active low. active low. Indicates whether or not there is a diskette in the unit. Indicates that the heads are located at track 0 of the diskette. Data pulses when reading the diskette Write Protect. High Density.we will delete 37 . Step.44 MB diskette is in the unit. Indicates that a 1. Enables writing. Motor on. pulses. www. X9 Pin 9 10 11 12 13 14 15 C IP N TR00 N MO N WG N STEP N HD N 0V Explanation Index.Troubleshooting Tools 3. 2 (Figure 3).if tort to your rights.please inform us.cadfamily.we will delete . see 3.4.Troubleshooting Tools MOTOR ON DRIVE SELECT STEP WRITE GATE WRITE DATA Write frequency MOTOR ON DRIVE SELECT STEP WRITE GATE READ DATA Read frequency Figure 4 Diagram of write and read frequencies.6 Teach pendant The data transmission signal complies with the EIA RS 422 standard.com 38 Product Manual The document is for study only. 3. X9 Pin 6 A DATA4=TP C DATA4-N=TP-N www.com EMail:cadserv21@hotmail. 4.8 Safety X9 Pin 27 A ENABLE9 C SPEED ENABLE 9: 5V when supply voltage is OK and the computers are OK (output from the robot computer to the panel unit.please inform us.cadfamily.17.com Product Manual The document is for study only.7 CAN X9 Pin 25 26 A CANRLY2 N CAN_H C CANRLY3 N CAN_L CANRLY2 N and CANRLY3 N respectively: 0V when CAN 2 or CAN 3 is active (see Installation and Commissioning.17.if tort to your rights. SPEED: 5V when one of the modes AUTO or MANUAL FULL SPEED is active (input to the robot computer from the panel unit).4. 24V when CAN 2 and CAN 3 are disconnected (see Installation and Commissioning.Troubleshooting Tools 3. section 3.we will delete 39 .3).3). 3. In this case the backplane fixed termination resistor is connected in. LED EN).com EMail:cadserv21@hotmail. section 3. www. com 40 Product Manual The document is for study only.please inform us.Troubleshooting Tools www.we will delete .com EMail:[email protected] tort to your rights. ................11 Disk Drive ..3 Main computer DSQC 361 and memory board DSQC 323/324 ........................................................................................................................................................................................................................................................................1.......................2 Tools...... 10 1..................................................................1 Status of the Panel unit........................................... 8 1...............................................................................10 Measurement System .......cadfamily................................................................1 Intermittent errors ..............................2 Robot system ..........1 Starting Troubleshooting Work..........9 Teach Pendant.................com EMail:cadserv21@hotmail................................. 11 www..............................................................8 Drive System and Motors.....5 Panel unit DSQC 331...........................................................5.........................................................6 Distributed I/O.................. 3 1......... 5 1..............................................Fault tracing guide CONTENTS Page 1 Fault tracing guide ......................................... 3 1.please inform us........we will delete 1 ............ 9 1............ 5 1..........12 Fuses....................................................... displayed on the teach pendant 6 1............................... 9 1....................... 11 1........................................... 10 1.............................................if tort to your rights........ 3 1.............................7 Serial Communication..........4 Robot computer DSQC 363 .... 4 1.......................... inputs and outputs.........1....... 4 1......................................................................... 3 1........com Product Manual The document is for study only.................. we will delete .com 2 Product Manual The document is for study only.please inform us.if tort to your rights.cadfamily.Fault tracing guide www.com EMail:cadserv21@hotmail. 1 Intermittent errors Unfortunately. which occur for different reasons. these are run in loops.. It may be necessary to run quite a number of test programs in order to pinpoint the error. which LEDs are lit.Oscilloscope . if there are any error messages there. which should make the error occur more frequently. you must be very experienced and have an in-depth knowledge of the control system.Recorder www. For example.we will delete 3 . intermittent errors sometimes occur and these can be difficult to remedy. On the basis of this error information. To identify the unit in which there is a fault.1. the wrist strap in the controller must be used to avoid ESD damage. Disturbances in the robot environment can affect cabling.if tort to your rights. heating problems. To make a correct error diagnosis of these particular cases.Multimeter . the robot’s behaviour. check whether something in the environment in which the robot is working also changes periodically.cadfamily. 1.com EMail:cadserv21@hotmail. Intermittent errors can also be caused by considerable temperature changes in the workshop. etc. you can start your analysis using the various tools. Never start off by wildly replacing boards or units since this can result in new errors being introduced into the system. test programs. the messages on the teach pendant. the following tools are required when troubleshooting: . loose connections. etc. dry joints.please inform us. etc. look at the control system’s error log.Normal shop tools .com Product Manual The document is for study only. available. This problem can occur anywhere in the robot and may be due to external interference. note and/or ask a qualified operator to note the status of all the LEDs. measuring points.1. it can be accessed from the Service menu. to note which error messages are displayed. etc. This section of the Product Manual is intended to provide support and guidance in any diagnostic work. if the cable screen connections are not intact or have been incorrectly connected. internal interference..1 Starting Troubleshooting Work Always start off by consulting a qualified operator and/or check any log books available to get some idea of what has happened. it may be caused by electrical interference from a large electric plant which only operates periodically. 1. 1.Fault tracing guide 1 Fault tracing guide Sometimes errors occur which neither refer to an error message nor can be remedied with the help of an error message. each time that type of error occurs. If an intermittent error occurs periodically. If possible.2 Tools Usually. When handling units and other electronic equipment in the controller. 0 X 7FFFFF When the error is in the memory board.if tort to your rights. an error code will be shown on the display. where it is not possible to directly pinpoint the unit that caused the problem. The memory board is an extension of the main computer memory. T1047 or T2010. which is connected to the VME bus and the local bus of the memory board.3 Main computer DSQC 361 and memory board DSQC 323/324 The main computer. the code is above 0 X 800 000. the robot computer releases the main computer when the robot computer’s diagnostics allows it and. i.com EMail:cadserv21@hotmail. For example. either a critical system failure has occurred or the main computer board or memory board is faulty.). If the red LEDs on the main computer light up (or do not turn off at initialisation). following this. F. all diagnostic monitoring is controlled by the main computer.2 Robot system In this instance the robot system means the entire robot (controller + manipulator) and process equipment.please inform us.e.com 4 Product Manual The document is for study only. At start-up. The read and write memories of the main computer are battery-backed. www. irrespective of whether a cold or warm start is performed.we will delete .Fault tracing guide 1. the main computer takes over the control of the system.cadfamily. Errors can occur in the form of several different errors where it is difficult to localise one particular error. 1. if the system cannot be cold-started. When the error is in the main computer. looks after the higher-level administrative work in the control system. a computer fault. These error codes also include a field called the At address. etc. which in turn contains an hexadecimal code that indicates on which board the erroneous memory circuit is located. The memory board has a LED. the hexadecimal code is in the following range: 0 X 000000 . Under normal operating conditions. If there is a memory error on one of these boards. which is lit and turned off by the main computer. this may be due to several different errors (the wrong diskette. www. chain 1 and 2 closed GENERAL STOP switch. see also section 1.4 Robot computer DSQC 363 The robot computer.5 Panel unit DSQC 331 The DSQC 331 Panel unit controls and monitors the dual operation chain.6 Network status. the error is probably in the robot computer.we will delete 5 . chain 1 and 2 closed AUTO STOP switch. which controls the system’s I/O. serial communication and teach pendant communication. axis control. see also section 1.cadfamily.Fault tracing guide 1. Unlit LEDs indicate the whereabouts of an error in the operation chain. making the error easy to locate in the system circuit diagram. The read and write memories of the robot computer are battery-backed.please inform us. The red LED on the front of the board goes off immediately when the system is reset and goes on again if an error is detected in the tests. normally green.6 EMERGENCY STOP.if tort to your rights. and the LED on the robot computer goes on. As mentioned above.com Product Manual The document is for study only. Its status is also indicated by LEDs at the upper part of the unit. If the system does not start at all. LED indications for DSQC 331 Marking EN MS NS ES 1 and 2 GS 1 and 2 AS 1 and 2 Colour Green Green/red Green/red Yellow Yellow Yellow Meaning Indicates “go ahead” from the control system Module status. 1. is the first unit to start after a cold or warm start. the robot computer releases the main computer when the preliminary diagnostics have given the go ahead-signal. chain 1 and 2 closed The LEDs are very useful when trying to locate errors in the operation chain. normally green. Over temperature of the motors is monitored by PTC inputs to the board.com EMail:cadserv21@hotmail. we will delete . • Call up the Units list by choosing View.cadfamily.please inform us.com EMail:cadserv21@hotmail. The location of the status signals are found in the circuit diagram.if tort to your rights. inputs and outputs. • Select the Safety unit. release brakes) and turn on duty time counter Turn on LED in motor-on push button Energise motor contactor chain 1 Energise motor contactor chain 2 Choose delayed turn off of auto stop Choose delayed turn off of emergency stop Choose delayed turn off of general stop www. regarding Panel unit.1 Status of the Panel unit. Outputs DO Name BRAKE MONLMP RUN CH1 RUN CH2 SOFT ASO SOFT ESO SOFT GSO Meaning when “1” is displayed Energise brake contactor (i.com 6 Product Manual The document is for study only.e.Fault tracing guide 1.5. displayed on the teach pendant • Select the I/O window. where outputs are marked with and inputs with See the table below. if tort to your rights. Auto operation Mode selector chain 2.we will delete . closed Motor contactor.please inform us.com Product Manual The document is for study only. Auto operation All switches in chain 1 closed All switches in chain 2 closed Enabling device chain 1 closed Enabling device chain 2 closed Emergency stop chain 1 closed Emergency stop chain 2 closed Enable from backplane External contactors closed Fan in power supply running General stop chain 1 closed General stop chain 2 closed Motor contactor. SOFT ASI SOFT ESI SOFT GSI TRFOTMP 24V panel Meaning when “1” is displayed Auto stop chain 1 closed Auto stop chain 2 closed Mode selector chain 1. chain 1.Fault tracing guide Inputs DI Name AS1 AS2 AUTO1 AUTO2 CH1 CH2 EN1 EN2 ES1 ES2 ENABLE EXTCONT FAN OK GS1 GS2 K1 K2 LIM1 LIM2 MAN2 MANFS2 MANORFS1 MON PB PTC PTC Ext. chain 2. Manual or manual full speed operation Motor-On push button pressed Over temperature in motors of manipulator Over temperature in external device Delayed turn off of auto stop (read back of digital output) Delayed turn off of emergency stop (read back of digital output) Delayed turn off of general stop (read back of digital output) Over temperature in main transformer 24V panel is higher than 22V 7 www. Manual full speed operation Mode selector chain 1. Manual operation Mode selector chain 2. closed Limit switch chain 1 closed Limit switch chain 2 closed Mode selector chain 2.cadfamily.com EMail:cadserv21@hotmail. or bus-off) Action Wait for connection Change MAC ID and/ or check CAN connection/cables 3. In the event of an error in the I/O communication to and from the robot.cadfamily. 4. via the CAN bus. not connected On-line. check as follows: 1.6 Distributed I/O I/O units communicate with the I/O computer. On the unit in question. See the table below regarding other conditions: MS LED is: Off Green Flashing green Flashing red/green Flashing red Red To indicate No power Normal condition Software configuration missing. Is I/O communication programmed in the current program? 2. incapable of communicating (duplicate MAC ID. The I/O channels can be read and activated from the I/O menu on the teach pendant. connections established Critical link failure.com EMail:cadserv21@hotmail. To activate the I/O units they must be defined in the system parameters. standby state Device self testing Minor fault (recoverable) Unrecoverable fault Configure device Wait for test to be completed Restart device Replace device Action Check 24 V CAN NS LED is: Off Flashing green Green Red To indicate Not powered/not on-line On-line.com 8 Product Manual The document is for study only. located on the robot computer board.we will delete . Check that the current I/O signal has the desired status using the I/O menu on the tech pendant display. www.Fault tracing guide 1. Check on all connectors and cabling from the I/O unit to the process connection. Check the I/O unit’s LED for the current input or output. If the output LED is not lit. 5. check that the 24 V I/O power supply is OK. the MS (Module status) and NS (Network status) LEDs must be lit with a fixed green colour.please inform us.if tort to your rights. which consists of rectifier.g.8 Drive System and Motors The drive system. An explanation of the available error messages can be found in the User’s Guide. check the cables and the connected equipment before doing anything else. drive unit and motor.we will delete 9 .com EMail:cadserv21@hotmail. The drive system is equipped with internal error supervision. If there is a problem. the unit should be replaced. If a drive unit or rectifier is faulty.com Product Manual The document is for study only. is controlled by the axis computer. See chapter 9. System and error messages.please inform us. 39XXX.Fault tracing guide 1. located on the robot computer board. Computer Rotor position Torque reference Serial measurement board DC link Drive Unit M R Figure 1 A schematic description of the drive system. 1.cadfamily. The communication can be tested using the integral test-program. An error is sent on via the robot computer and can be read on the teach pendant display as an error message. section 3.7 Serial Communication The most common causes of errors in serial communication are faulty cables (e. www. Internal troubleshooting cannot be performed in the operating environment. mixed-up send and receive signals) and transfer rates (baud rates). after strapping the input to the output. error no.if tort to your rights. or data widths that are incorrectly set. com EMail:[email protected] Measurement System The measurement system comprises an axis computer. Common causes of errors in the measurement system are line breakdown.if tort to your rights. Transmission errors are detected by the system’s error control. Note that it is necessary to re-calibrate after the resolver lines have been disconnected. 1. resolver errors and measurement board interference. The board is located in the manipulator and is battery-backed.cadfamily. The board is supplied from 24 V SYS via a fuse on the back plane. see chapter 9 for more detailed information. If it is positioned too close to a source of interference. one or more serial measurement boards and resolvers. If the resolver connections are disconnected or if the battery goes dead after the robot has been stationary for a long period of time. setting the counters to zero. the manipulator’s axis positions will not be stored and must be updated. there is a risk of an error. which has its own measurement board. using the teach pendant.9 Teach Pendant The teach pendant communicates with the robot computer via a cable. Communication with the axis computer takes place across a differential serial link (RS 485). try first adjusting the contrast. Measuring points for the measurement system are located on the backplane. The measurement system contains information on the position of the axes and this information is continuously updated during operation. and if this does not help check the 24 V power supply.Fault tracing guide 1. For measuring points for the teach pendant communication signals. X9 Maintenance plug. Communication errors between the teach pendant and the I/O computer are indicated by an error message on the teach pendant. The latter type of error relates to the 7th axis. see chapter 9. The serial measurement board is used to collect resolver data. If you try to start program execution without doing the above.com 10 Product Manual The document is for study only. This cable is also used for the +24 V supply and the dual operation chain. which alerts and stops program execution if necessary. If the display is not illuminated.please inform us. This applies even if the manipulator axes have not been moved. The axis positions are updated by manually jogging the manipulator to the synchronised position and then. the system will give an alarm to indicate that the system is not calibrated.we will delete . www. 24 panel. The cabling from customer 24 V supply is protected by a 2A fuse on terminal XT31 in the upper compartment of the controller. The panel unit has one PTC fuse to protect the motor on chains. Unmarked. cheap diskettes can be of very poor quality. format a new. the disk drive will probably have to be replaced. on the transformer. When replacing the disk drive. high quality diskette in the robot and check to see whether the error disappears. before replacing the drive. There are also two fuses for customer AC supplies.12 Fuses There is one automatic three-phase 20 A fuse that supplies the DC-link in the MOTORS ON state. see chapter 9. The power is supplied by a separate cable. If the error is still present.11 Disk Drive The disk drive is controlled by the I/O computer via a flat cable. Measuring points are available on the backplane: X9 Maintenance plug.if tort to your rights. There is also a automatic three-phase 10 A fuse that supplies the power supply unit.Serial measurement board 1 .com EMail:cadserv21@hotmail. Note that the power supply unit DSQC 374 is provided with a short circuit energy limitation which makes the fuse unnecessary. 1.15 A and one 6.Serial measurement board 2 . However.cadfamily. check that the strapping is set correctly on the unit. external I/O The fuses protect against 24 V short-circuits and return to the normal state when there is no longer a risk of short-circuiting.CAN3. www. inputs and outputs. If the disk drive is completely dead. Compare with the faulty drive being replaced.com Product Manual The document is for study only. displayed on the teach pendant side 6. Common types of error are read and write errors. see Status of the Panel unit.please inform us. An open fuse is indicated on the teach pendant. In the event of a read and/or write error. one 3. generally caused by faulty diskettes. check the flat cable first.CAN2.Fault tracing guide 1. NB: Never use diskettes without a manufacturer’s mark. check the supply voltage connection to the disk drive to see that it is +5 V.we will delete 11 . manipulator I/O .3 A. The backplane has four PTC resistance fuses: . cadfamily.we will delete .please inform us.com 12 Product Manual The document is for study only.if tort to your rights.com EMail:[email protected] tracing guide www. cadfamily.please inform us.com EMail:[email protected] The document is for study only.www.if tort to your rights.we will delete . please inform us.if tort to your rights.www.com The document is for study only.we will delete .com EMail:[email protected]. com EMail:[email protected] will delete .if tort to your rights.www.cadfamily.please inform us.com The document is for study only. cadfamily.www.we will delete .please inform us.com EMail:[email protected] tort to your rights.com The document is for study only. if tort to your rights.com The document is for study only.we will delete .cadfamily.www.com EMail:[email protected] inform us. we will delete .www.com EMail:[email protected] inform us.com The document is for study only.if tort to your rights. www.com EMail:[email protected] will delete .if tort to your rights.please inform us.com The document is for study only. we will delete .com EMail:[email protected] The document is for study only.if tort to your rights.cadfamily.www.please inform us. cadfamily.please inform us.we will delete .com EMail:[email protected] The document is for study only.www.if tort to your rights. if tort to your rights.cadfamily.please inform us.we will delete .com The document is for study only.www.com EMail:cadserv21@hotmail. please inform us.com The document is for study only.www.if tort to your rights.cadfamily.com EMail:[email protected] will delete . we will delete .com EMail:[email protected] The document is for study only.please inform us.cadfamily.if tort to your rights. com The document is for study only.please inform us.if tort to your rights.com EMail:[email protected] will delete .www. we will delete .com EMail:[email protected] The document is for study only.if tort to your rights.please inform us. com EMail:[email protected] The document is for study only.please inform us.cadfamily.we will delete .if tort to your rights. we will delete .www.com EMail:[email protected] inform us.com The document is for study only.cadfamily.if tort to your rights. www.please inform us.cadfamily.com The document is for study only.if tort to your rights.we will delete .com EMail:cadserv21@hotmail. if tort to your rights.we will delete .com EMail:[email protected] inform us.www.com The document is for study only. we will delete .www.com The document is for study only.please inform us.cadfamily.com EMail:[email protected] tort to your rights. com EMail:[email protected] will delete .please inform us.cadfamily.com The document is for study only.if tort to your rights.www. www.please inform us.com The document is for study only.we will delete .if tort to your rights.com EMail:[email protected]. com EMail:[email protected] will delete .please inform us.cadfamily.com The document is for study only.if tort to your rights. we will delete .www.if tort to your rights.please inform us.com EMail:[email protected] The document is for study only. if tort to your rights.www.com EMail:[email protected] inform us.com The document is for study only.we will delete .cadfamily. com The document is for study only.if tort to your rights.com EMail:[email protected] inform us.we will delete .www.cadfamily. we will delete .com EMail:[email protected] The document is for study only.if tort to your rights.please inform us.www. cadfamily.we will delete .if tort to your rights.www.please inform us.com EMail:[email protected] The document is for study only. please inform us.cadfamily.com The document is for study only.www.if tort to your rights.com EMail:[email protected] will delete . com The document is for study only.we will delete .www.com EMail:[email protected] tort to your rights.cadfamily.please inform us. cadfamily.www.please inform us.com EMail:[email protected] will delete .com The document is for study only.if tort to your rights. com EMail:[email protected] inform us.we will delete .www.if tort to your rights.com The document is for study only. com The document is for study only.if tort to your rights.we will delete .cadfamily.please inform us.com EMail:[email protected]. we will delete .com The document is for study only.if tort to your rights.please inform us.www.com EMail:[email protected]. com The document is for study only.we will delete .com EMail:[email protected] tort to your rights.cadfamily.please inform us.www. if tort to your rights.com The document is for study only.please inform us.we will delete .com EMail:[email protected]. we will delete .if tort to your rights.please inform us.com EMail:[email protected] The document is for study only.www. cadfamily.com EMail:[email protected] tort to your rights.com The document is for study only.please inform us.we will delete . we will delete .www.cadfamily.com The document is for study only.please inform us.com EMail:[email protected] tort to your rights. please inform us.if tort to your rights.com EMail:[email protected] will delete .www.com The document is for study only. cadfamily.if tort to your rights.please inform us.www.com The document is for study only.we will delete .com EMail:cadserv21@hotmail. if tort to your rights.cadfamily.com The document is for study only.please inform us.www.we will delete .com EMail:cadserv21@hotmail. com EMail:[email protected] inform us.we will delete .if tort to your rights.cadfamily.www.com The document is for study only. we will delete .if tort to your rights.com EMail:[email protected] The document is for study only.please inform us. com EMail:[email protected] The document is for study only.please inform us.if tort to your rights.cadfamily.we will delete .www. if tort to your rights.com EMail:[email protected] will delete .please inform us.www.com The document is for study only.cadfamily. please inform us.cadfamily.we will delete .com The document is for study only.if tort to your rights.www.com EMail:cadserv21@hotmail. if tort to your rights.www.cadfamily.com The document is for study only.please inform us.com EMail:[email protected] will delete . cadfamily.www.please inform us.com The document is for study only.if tort to your rights.com EMail:[email protected] will delete . com The document is for study only.com EMail:[email protected] inform us.if tort to your rights.cadfamily.we will delete .www. www.com The document is for study only.cadfamily.if tort to your rights.please inform us.com EMail:[email protected] will delete . com The document is for study only.if tort to your rights.com EMail:[email protected] will delete .please inform us.www. www.cadfamily.please inform us.com The document is for study only.we will delete .if tort to your rights.com EMail:cadserv21@hotmail. we will delete .com EMail:[email protected] The document is for study only.cadfamily.www.please inform us.if tort to your rights. if tort to your rights.we will delete .cadfamily.com EMail:[email protected] The document is for study only.please inform us. we will delete .cadfamily.com EMail:[email protected] The document is for study only.if tort to your rights.www.please inform us. we will delete .www.com EMail:[email protected] tort to your rights.cadfamily.please inform us.com The document is for study only. com EMail:[email protected] tort to your rights.www.we will delete .please inform us.com The document is for study only. com EMail:[email protected] tort to your rights.www.please inform us.we will delete .com The document is for study only. com EMail:[email protected] tort to your rights.please inform us.www.com The document is for study only.cadfamily.we will delete . cadfamily.com The document is for study only.www.if tort to your rights.please inform us.we will delete .com EMail:cadserv21@hotmail. we will delete .com EMail:[email protected] tort to your rights.cadfamily.please inform us.com The document is for study only.www. com EMail:[email protected] tort to your rights.com The document is for study only.www.we will delete .cadfamily.please inform us. com EMail:[email protected] will delete .cadfamily.com The document is for study only.please inform us.if tort to your rights. cadfamily.com EMail:[email protected] inform us.if tort to your rights.www.we will delete .com The document is for study only. com EMail:[email protected] The document is for study only.please inform us.cadfamily.we will delete .if tort to your rights. if tort to your rights.we will delete .please inform us.com EMail:[email protected] The document is for study only. www.com EMail:[email protected] tort to your rights.com The document is for study only.we will delete .cadfamily.please inform us. www.com EMail:[email protected] tort to your rights.com The document is for study only.please inform us.we will delete .cadfamily. please inform us.we will delete .www.com The document is for study only.com EMail:[email protected] tort to your rights. cadfamily.we will delete .if tort to your rights.please inform us.com The document is for study only.com EMail:[email protected]. cadfamily.com The document is for study only.please inform us.we will delete .com EMail:[email protected] tort to your rights. www.please inform us.cadfamily.com EMail:[email protected] tort to your rights.we will delete .com The document is for study only. if tort to your rights.www.com The document is for study only.com EMail:[email protected] inform us.cadfamily.we will delete . we will delete .please inform us.cadfamily.com The document is for study only.www.com EMail:[email protected] tort to your rights. www.we will delete .com The document is for study only.cadfamily.please inform us.if tort to your rights.com EMail:cadserv21@hotmail. please inform us.if tort to your rights.we will delete .com EMail:[email protected] The document is for study only.www. we will delete .com EMail:[email protected] inform us.com The document is for study only.cadfamily.if tort to your rights. please inform us.com EMail:[email protected] will delete .if tort to your rights.com The document is for study only.cadfamily.www. if tort to your rights.cadfamily.com The document is for study only.we will delete .www.please inform us.com EMail:cadserv21@hotmail. www.com EMail:[email protected] inform us.we will delete .cadfamily.if tort to your rights.com The document is for study only. com EMail:[email protected] tort to your rights.com The document is for study only.cadfamily.please inform us.we will delete . com The document is for study only.com EMail:[email protected] inform us.cadfamily.www.if tort to your rights.we will delete . if tort to your rights.please inform us.cadfamily.we will delete .com EMail:[email protected] The document is for study only.www. www.we will delete .cadfamily.please inform us.if tort to your rights.com The document is for study only.com EMail:cadserv21@hotmail. please inform us.com The document is for study only.www.com EMail:[email protected] will delete .if tort to your rights. com The document is for study only.we will delete .please inform us.cadfamily.com EMail:[email protected] tort to your rights.www. www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete com EMail:[email protected] inform us.if tort to your rights.com The document is for study only.we will delete .www. we will delete .com The document is for study only.com EMail:[email protected] inform us.cadfamily.if tort to your rights. please inform us.com EMail:[email protected] tort to your rights.www.we will delete .com The document is for study only. com The document is for study only.we will delete .if tort to your rights.www.please inform us.com EMail:[email protected]. we will delete .please inform us.com EMail:[email protected] The document is for study only.www.if tort to your rights.cadfamily. cadfamily.com EMail:[email protected] The document is for study only.please inform us.www.if tort to your rights.we will delete . www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete cadfamily.com The document is for study only.com EMail:[email protected] will delete .please inform us.www.if tort to your rights. com EMail:[email protected] will delete .please inform us.www.if tort to your rights.com The document is for study only. com The document is for study only.cadfamily.com EMail:[email protected] tort to your rights.we will delete .www.please inform us. we will delete .if tort to your rights.cadfamily.com EMail:[email protected] The document is for study only.www.please inform us. www.cadfamily.we will delete .if tort to your rights.com EMail:[email protected] inform us.com The document is for study only. com The document is for study only.please inform us.www.cadfamily.we will delete .com EMail:[email protected] tort to your rights. if tort to your rights.com The document is for study only.com EMail:[email protected] inform us.cadfamily.www.we will delete . cadfamily.we will delete .www.if tort to your rights.com The document is for study only.com EMail:[email protected] inform us. if tort to your rights.com EMail:[email protected] will delete .please inform us.com The document is for study only. com EMail:[email protected] inform us.if tort to your rights.we will delete .com The document is for study only.cadfamily.www. please inform us.www.cadfamily.com The document is for study only.com EMail:[email protected] tort to your rights.we will delete . please inform us.com The document is for study only.we will delete .www.com EMail:[email protected] tort to your rights. com The document is for study only.please inform us.www.if tort to your rights.we will delete .com EMail:[email protected]. com The document is for study only.www.please inform us.cadfamily.com EMail:[email protected] tort to your rights.we will delete . if tort to your rights.www.we will delete .com EMail:[email protected] The document is for study only.please inform us.cadfamily. cadfamily.if tort to your rights.com The document is for study only.we will delete .please inform us.com EMail:[email protected]. we will delete .com EMail:[email protected] tort to your rights.www.com The document is for study only.cadfamily.please inform us. please inform us.com The document is for study only.com EMail:[email protected] tort to your rights.we will delete .cadfamily. .. 30 6...3....................................3 Changing the drive gear on the tubular shaft .................................3 Replacing the mechanical stop .................if tort to your rights...... 12 2........................ 20 4..4 Changing bearings of the tubular shaft .......................................................2 The Wrist and Axes 5 and 6 ..................1............................................ 21 4........ 6 1......cadfamily.1 Changing the motor for axis 3 ............... 11 2...........................................2 Seals ......1....................we will delete 1 .................. 5 1..........................................com Product Manual IRB 2400 The document is for study only.....4 Instructions for tightening screw joints .................................................................1 Changing the motor....................... 29 6......................................................................................................... 27 5.................. 5 1.................................................................. 20 4.........................2 Changing the gearbox.......................................................................................1............ 29 6............................ 16 3....................................... 9 2 Axis 1 ..................................................5.............. 3 1...................................1 Screws with slotted or cross recessed head........ 25 5..................................................................Repairs CONTENTS Page 1 General Description ............................................................... 16 3...........please inform us..............5........................................................2 Caution.....1 Axis 4................................................................................................................................................................................ 13 3 Axis 2 ................................................1............... 33 6...................................................................................................................................................................................................................................................................................2 Dismounting the wrist ........................ 15 3................................................ 8 1................................................................... 22 5 Axes 4-6 (IRB 2400/10/16) ................................................................................................................................ 9 1.................................................................................................3.....................................................com EMail:[email protected] Changing the bearing in the lower arm ...................................................................2 Screws with hexagon socket head.................................................... 9 1. 31 6..........................................................................................................................................1 Replacing the motor for axis 1 .............2 Changing the gearbox................3 Dismounting the mechanical stop for axis 4 ..........5 Dismantling the complete upper arm....... 18 4 Axis 3 ...................................................................................................... 5 1............. 19 4......1 Instructions for reading the following chapters......................... 29 6....................................2 Changing the intermediate gear including sealing...1 Changing the motor for axis 2 ..................................................3 Dismantling the lower arm ..............................4 Changing the tie rod ...............................3 Fitting new bearings and seals......................................1 Replacing the motor.......2 Changing the gearbox..................... 11 2....................................5 Tightening torques .......................... 33 www............................................................3 Dismantling the parallel arm .............. 25 5........................................... 28 6 Axes 4-6 (IRB 2400L).......................................... 19 4..................................1 Bearings . 4 1......................................... 15 3............................................... ............................................................................................... 46 10...................2..... 43 10 Oil change in gearboxes............... axes 5-6 (IRB 2400L) ............................................ 48 11 Calibration ...................cadfamily.. 61 11..........................................................................................1 Oil in gearboxes 1-3 (IRB 2400L/10/16) .......................... 47 10....2..............................................................................7 Changing and checking the oil in gearbox 4 (IRB 2400L) ........ 49 11.........2 and 3..... 5 and 6..........1 General description................................ 59 11............. 34 6.........................................................3 Changing the cabling in axes 4........................................................................................................................... 46 10...................2 Changing the cabling in axes 1.....................3 Oil in gearboxes 4-6 (IRB 2400L) .......................... 39 8........................................Repairs CONTENTS Page 6.......9 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400L) .............................................................................................2 Oil in gearboxes 4-6 (IRB 2400/10/16).......................if tort to your rights............................. 39 8.....4 Changing the signal cabling axis 4................................................... axes 4-6 (IRB 2400/10/16) ..........5 Alternative calibration positions. 40 8............................. 49 11........... 45 10.................7 Operating the robot..................................... 46 10.................................................................... 45 10....... 49 11.......................................................................6 Calibration equipment .................... 45 10..............................................2............................................................................................... 43 9.. 39 8.1 Dismantling the wrist.......................4 Oil plugs..2 Adjustment procedure using calibration equipment (fine calibration)........2 Changing the drive shaft unit... option 04y......................................................................... 34 6............we will delete ........................... 47 10.......1 General ...........1 General...............8 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400/10/16) ...........................................com 2 Product Manual IRB 2400 The document is for study only.............. 55 11.....3 Changing the motor or driving belt of axes 5 and 6 ........... 61 www.....................3 Setting the calibration marks on the manipulator...............................................6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16)............................ gear belts or motors ....................................... 37 8 Cabling and Measuring board ................................................................................................... 37 7.........com EMail:[email protected] Checking the calibration position ..................5 Oil plugs.............please inform us.. 45 10......1 Changing serial measuring board . 40 9 Motor units ......................... 59 11................................ 36 7 Push-button unit for brake release...................................................................................................... When any type of maintenance work is carried out. The wrist is bolted to the tip of the upper arm and includes axes 5 and 6. Mechanical brakes. The Mechanical System has 6 axes which make its movements very flexible. The lower arm. located on the upper arm. Axis 2 provides the lower arm’s reciprocating motion. electrically released. lock the motor units when the robot is inoperative for more than 3 minutes during both automatic operation and manual operation. rotates the upper arm.cadfamily. Make sure also that the safety instructions in this manual are followed when starting to operate the robot. A brake release unit can be connected as described in chapter 7. The signal cabling feeds the various control parameters. driving them through gearboxes.we will delete 3 . A connection is supplied for various customer tools on the tip of the wrist in the turn disc.com The document is for study only. The tool (or manipulator) can be pneumatically controlled by means of an external air supply (optional extra). Axis 5 is used to tilt and axis 6 to turn. Axis 1 rotates the manipulator. such as axis positions. These axes form a cross. The power cabling feeds the motor units of the manipulator axes. Push-button unit for brake release. The signals to/ from the tool can be supplied via internal customer connections (optional extras). Product Manual IRB 2400 www. Axis 3 raises the upper arm of the manipulator. When servicing the manipulator. Take special care when manually operating the brakes.com EMail:cadserv21@hotmail. it is helpful to service the following parts separately: • The Electrical System • The Motor Units • The Mechanical System The Electrical System is routed through the entire manipulator and is made up of two main cabling systems: the power cabling and signal cabling.if tort to your rights. The parallel bracket is mounted on bearings in the radius rod and in the upper arm. etc. Note that the control cabinet must be switched off during all maintenance work on the manipulator.please inform us. resolver unit). to enable movement of the axes. The AC Motor Units provide the motive power for the various manipulator axes. together with the radius rod and the parallel bracket. Axis 4. cabling. Servicing the mechanical unit is described in the subsequent chapters. form a parallelogram relative to the upper arm.Repairs General Description 1 General Description The IRB 2400 industrial robot system comprises two separate units: the control cabinet and the manipulator. the calibration position of the manipulator must be checked before the robot is returned to the operational mode. motor revs. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards. 1 Instructions for reading the following chapters The subsequent chapters describe the type of on-site maintenance that can be performed by the customer’s own maintenance staff. these numbers are referred to in angle brackets < >. The information in the following chapters should be used only after an appropriate course has been completed. Calibration. It may be necessary to use conventional tools. Conventional tools are not discussed in this manual. Calibration: The robot must be re-calibrated when a mechanical unit or part of one is replaced. These jobs involve replacing the faulty module or component on-site. Maintenance jobs which require the use of special tools are. the foldout’s number is included in the numeric reference to its item number. for example: <5/19> or <10:2/5>. The foldouts also include other information such as the article number. Foldouts: The chapter on spare parts comes with a number of foldouts which illustrate the parts of the robot. These foldouts are provided in order to make it easier for you to quickly identify both the type of service required and the make-up of the various parts and components. or when the power supply between a measurement board and resolver is interrupted. on the other hand.cadfamily. designation and related data. Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. since it is assumed that maintenance staff have sufficient basic technical competence.. After performing such work. the calibration position of the robot must be checked as described in chapter 11. such as sockets and ratchet spanners. This procedure is described in detail in chapter 11. The digit(s) before the stroke refer to the foldout number.General Description Repairs 1. when the motor and feedback unit is disconnected. If a reference is made to a foldout. 4 Product Manual IRB 2400 www. In the subsequent sections. Tools: Two types of tools are required for the various maintenance jobs. when a resolver error occurs.com The document is for study only.com EMail:cadserv21@hotmail. etc.we will delete . The faulty component is then transported to ABB Flexible Automation for service. described in this manual. NB: This manual is not construed as a substitute for a proper training course. or special tools.if tort to your rights.please inform us. depending on the type of servicing. The item numbers of the parts are also shown on the foldouts. other than that specified in the paragraph title. Calibration. Any work on the robot signal cabling may cause the robot to move to the wrong positions. Cast parts must be free from foundry sand. 6. 3. It is important to position the bearings correctly.Repairs General Description 1. Greasing bearings 8. Make sure that all parts of the bearing are free from burr dust.2 Caution The mechanical unit contains several parts which are too heavy to lift manually.cadfamily.com The document is for study only. because this directly affects the service life of the bearing. The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange. Tapered bearings 4. The bearing should be tightened gradually until the recommended pre-tensioning is attained.1 Bearings 1.please inform us. Grooved ball bearings should be greased on both sides. such as 3HAB 3537-1. in order to prevent dust and grit getting into the bearing. A high quality lubricating grease. Bearing rings. it is important that suitable lifting equipment is available.com EMail:cadserv21@hotmail. 5.if tort to your rights. Product Manual IRB 2400 www. As these parts must be moved with precision during any maintenance and repair work. Bearings must be greased after they are fitted.we will delete 5 . 7. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space. 1. 2. Do not unwrap new bearings until just before assembly. races and roller parts must not under any circumstances be subjected to direct impact. 9. Extreme cleanliness is necessary throughout. should be used.3 Fitting new bearings and seals 1. The roller parts must not be subjected to any pressure that is created during the assembly.3. grinding dust and any other contamination. The roller parts must be rotated a specified number of turns both before pretensioning and during pre-tensioning. 11. Always use an assembling tool to fit the seal.3. Normally the bearings should not be completely filled with grease. 3. 10. Make sure that the grease is handled and stored correctly. However.we will delete . The most common cause of leakage is incorrect installation. if there is space on both sides of the bearing. The seals must either be kept in their original packages or be protected well. 1. Seals and gears must be fitted on clean workbenches.cadfamily. Tapered roller bearings and axial needle bearings should be greased when they are split.please inform us. 4. 6 Product Manual IRB 2400 www. it may start to leak when pumping starts. Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. 12. 7. 70-80% of the available volume of the bearing must be filled with grease during operation. 6. Never hammer directly on the seal because this will cause it to leak. The space between the dust tongue and sealing lip should be 2/3 filled with grease of the type 3HAB 3537-1. 5. etc. 13. to avoid contamination. The seal surfaces must be protected during transportation and assembly.com EMail:cadserv21@hotmail. 8. If the seal is scratched or damaged in such a way that it may cause leakage in the future.2 Seals 1. it must be replaced. Fit the seal correctly.General Description Repairs 10. as surplus grease will be released from the bearing on start up. The seal surfaces must be inspected before installation.com The document is for study only. The rubber coated external diameter must also be greased. If it is fitted incorrectly. Rotating seals 2. key-ways. The seal must also be checked before it is fitted to ensure that: • the seal edge is not damaged (feel the edge with your finger nail) • the correct type of seal is used (has a cut-off edge) • there is no other damage. 9. Use a protective sleeve on the sealing edge during assembly. when sliding over threads. it can be filled completely with grease when it is fitted.if tort to your rights. they must not be used as they will cause leakage. The surfaces must be cleaned properly in the manner recommended by ABB ROBOTICS. they will cause leakage. 21. Make sure the correct O-ring size is used. Check the O-ring grooves.please inform us.com The document is for study only.cadfamily. O-rings 17. 15. Grease the O-ring with 3HAB 3537-1 before fitting it. If the flange surfaces are defective. 20. without pores and free of dust and grime. preferably using a brush. 13. 22. 19. The evenness can be easily checked using a gauge on the fitted joint (without sealing compound).if tort to your rights.com EMail:cadserv21@hotmail. Product Manual IRB 2400 www. etc. If any of the parts fitted are defective. 16. Check the flange surfaces. Tighten the screws evenly around the flange joint. 14. Check the O-ring for surface defects and burrs.we will delete 7 . 18. 12. and check that it has the correct shape. Make sure that the joint is not subjected to loading until the sealing compound has attained the hardness specified in the materials specification. Defective O-rings and O-ring grooves must not be used. Tighten the screws evenly. The grooves must be geometrically correct. Distribute the sealing compound evenly over the surface.Repairs Flange seals and static seals General Description 11. The surface must be even and have no pores. The surfaces must be even and free from burr dust (caused by incorrect machining). Screws can also be treated with Molycote 1000. Screws sized M8 or larger should be tightened with a torque wrench.we will delete . Molycote 1000 should only be used when specified in the text. The instructions do not apply to screw joints made of soft or brittle materials. When handling screws treated with Gleitmo. these should first be lubricated with Molycote 1000 and then tightened to the specified torque. Screws treated with Gleitmo All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo. if possible. the same specifications as for class 8. without using torque measurement tools. When screwing in new screws without Gleitmo. protective gloves of nitrile rubber type should be used. are applicable. Screws sized M6 or smaller may be tightened to the correct torque by personnel with sufficient mechanical training.8.com The document is for study only. Assembly Screw threads sized M8 or larger should preferably be lubricated with oil.cadfamily. Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. For screws with a property class higher than 8.General Description Repairs 1. unless otherwise stated.please inform us.4 Instructions for tightening screw joints General It is extremely important that all screw joints are tightened using the correct torque.8.com EMail:cadserv21@hotmail. Application The following tightening torques must be used for all screw joints made of metallic materials – unless otherwise specified in the text. 8 Product Manual IRB 2400 www.if tort to your rights. 2 Screws with hexagon socket head Tightening torque .we will delete 9 .5.com EMail:[email protected] inform us.0 1.5 5.com The document is for study only.Nm Dimension Class 8.25 0.1 Screws with slotted or cross recessed head Tightening torque .5 Tightening torques 1.Nm Dimension M 2.5.8 “Dry” 6 10 24 47 82 200 28 55 95 235 15 35 70 120 300 Class 10.9 Molycote 1000 Gleitmo 610 M5 M6 M8 M 10 M 12 M 16 Product Manual IRB 2400 www.8 “Dry” 0.2 2.cadfamily.Repairs General Description 1.9 Molycote 1000 Gleitmo 610 Class 12.5 M3 M4 M5 M6 Class 4.5 1.if tort to your rights. please inform us.com EMail:[email protected] tort to your rights.we will delete .General Description Repairs 10 Product Manual IRB 2400 www.cadfamily.com The document is for study only. Loosen connectors R3. Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3. 14. 7. 4. which corresponds to a reading on the dial indicator of 0. Pull gently in one direction. The motor and the drive gear constitute one unit.) Product Manual IRB 2400 www. To assemble: 6. tighten screws <1/9> using a torque of 2 Nm. 3.1 Replacing the motor for axis 1 See foldouts 1 and 5 in the list of spare parts. Remove the cover of the connection box.Repairs Axis 1 2 Axis 1 2. Note the position of the motor before removing it. Check that the assembly surfaces are clean and the motor unscratched. 11.FB1. Install the motor. Mount the O-ring <1/6>. The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft.MP1 connector. with help of the tool. Note the position of the motor 9.02 mm.com The document is for study only. 10. To dismantle: 1. 5. Remove the connection box by unscrewing <5/137>. Note the reading.13 mm.cadfamily. 2.if tort to your rights. Set the gear play to 0.com EMail:cadserv21@hotmail. 3HAB 7887-1 at the rear of the motor. Place the tip of a dial indicator against the scribed mark on the measuring tool. 8. (The gear must not turn. Turn the motor shaft a couple of turns. Loosen the motor by unscrewing <1/9>.please inform us. Mount tool no.we will delete 11 . 12. 13.MP1 and R3. 5. Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate <3/102>.com EMail:cadserv21@hotmail. The gearbox is not normally serviced or adjusted. Tighten screw <1/9> with a torque of 15 Nm. 17.3. 16. Remove the tie rod as described in chapter 4. forms a complete unit. Remove the cabling and serial measuring boards as described in chapter 8. Calibrate the robot as specified in chapter 11.2 Changing the gearbox Axis 1 gearbox is of the conventional type. manufactured with high precision. Tightening torque: Motor attaching screws.if tort to your rights. 12 Product Manual IRB 2400 www.please inform us. Dismantling the complete upper arm.1. See foldouts 1.3.02 mm which corresponds to a reading on the dial indicator of 0.we will delete . Remove the motors on axes 1.13 mm. then the whole unit must be changed. Connect the cabling. The gear play should be 0. Dismantling the lower arm. Fill with oil. chapter 3.com The document is for study only. 6.4.1. Dismantle the lower arm as described in chapter 3. 3. and together with the gearboxes for axes 2 and 3. 4. Oil change in gearboxes. 7. Make sure that the foot is stable. 2 and 3 as described in sections chapter 2. Changing the tie rod.1. item 9: 15 Nm 2. To dismantle: 1. Cabling and Measuring board. Note: If there is reason to change a gearbox on any of the axes 1. Changing the motor for axis 2 and chapter 4. Dismantle the upper arm as described in chapter 4. Then gently knock on the tool in the other direction and note the reading. 19. 2. 2 and 3 in the list of spare parts. Remove the parallel arm as described in chapter 4. Changing the motor for axis 3. Calibration. Dismantling the parallel arm. The difference in reading = gear play. See chapter 10.5.cadfamily. 2 or 3. 18. Replacing the motor for axis 1.Axis 1 Repairs 15. com The document is for study only. 2. Place a new stop in position.3 Replacing the mechanical stop See foldout 1 in the list of spare parts. 13.com EMail:cadserv21@hotmail. Replace the parallel arm as described in chapter 4. Product Manual IRB 2400 www. Remove screw <134>.4. Replace the lower arm as described in chapter 3. 19. Undo screws <1/3>. Separate the base from the gearbox unit. Replace the upper arm as described in chapter 4. Axis 1 To assemble: 10. Lift the stop away. Tighten using a torque of 54 Nm. Changing the tie rod. Replace the cabling as described in chapter 8. Raise the base. Place a new gearbox unit on the table.5. Dismantling the parallel arm.cadfamily.3. Cabling and Measuring board. Dismantling the lower arm 16. 9. 17. Calibrate the robot as described in chapter 11. Screw in the screws <1/3> together with their washers <1/4>. To assemble: 3.3. Calibration. 11. 14. If the stop pin is bent.if tort to your rights. Replace the bottom plate <3/102> using screws <3/120>.we will delete 13 .Repairs 8. item <1/3>: 54 Nm 2. 15. Turn the base. Tightening torque: Screwed joint of base/gearbox unit. 1. 20.please inform us. 18. 12. Replace the tie rod as described in chapter 4. Tighten screw <134>. Dismantling the complete upper arm. 4. it must be replaced. Axis 1 Repairs 14 Product Manual IRB 2400 www.cadfamily.com EMail:[email protected] will delete .if tort to your rights.please inform us.com The document is for study only. Repairs Axis 2 3 Axis 2 3. 8.02 mm.B. 1/9> using a torque of 2 Nm.if tort to your rights. 4. To dismantle: Lock the arm system before dismantling the motor.com EMail:cadserv21@hotmail. 3HAB 7887-1 at the rear of the motor.com The document is for study only. 14. Set the gear play to 0. the brake is located in the motor. (The gear must not turn. 2. 3. Remove the connection box by unscrewing <5/137>.we will delete 15 . N. Mount tool no. Place the tip of a dial indicator against the scribed mark on the measuring tool. 12.cadfamily. tighten screws <1/8>. Note the reading. Note the position of the motor before removing it.MP2 and R3. Check that the assembly surfaces are clean and the motor unscratched. 1. 5.please inform us. The oil will start to run out. Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3. Loosen the motor by unscrewing <1/8. Remove the cover of the connection box. The motor and the drive gear constitute one unit. Turn the motor shaft a couple of turns. which corresponds to a reading on the dial indicator of 0. To assemble: 6. with help of the tool. Mount the O-ring <1/6>.MP1 connector.13 mm. Loosen connectors R3. 1/9>.1 Changing the motor for axis 2 See foldouts 1 and 5 in the list of spare parts. 9.FB2. Install the motor. 13.) Product Manual IRB 2400 www. 10. 7. 11. Note the position of the motor and the location of the two screws <1/8>. The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft. Pull gently in one direction. 16. The gear play should be 0. Note: If there is reason to change a gearbox on any of the axes 1. and together with the gearbox for axes 1 and 3. Tightening torque: The motor’s fixing screws. Dismantling the complete upper arm. manufactured with high precision. Then gently knock on the tool in the other direction and note the reading. Changing the gearbox. 3. Remove the parallel arm as in chapter 4. The gearbox is not normally serviced or adjusted.5. 17. 5. Tighten screw <1/8.we will delete .com EMail:cadserv21@hotmail. 19. 1/9> with a torque of 15 Nm. 2 or 3. Dismantle the upper arm as in chapter 4. To dismantle: 1. 2.if tort to your rights. 16 Product Manual IRB 2400 www. 3. forms a complete unit. Loosen screws <12>.3. Oil change in gearboxes. 18.cadfamily.2.02 mm which corresponds to a reading on the dial indicator of 0. Remove the cabling down to axis 1 as in chapter 8.please inform us. 4. Cabling and Measuring board. Fill with oil. Calibrate the robot as specified in chapter 11. Calibration. item 8. 9: 15 Nm 3. See chapter 10. The difference in reading = gear play. To dismantle: See chapter 2. Take off the lower arm.13 mm. 6. Connect the cabling.2 Changing the gearbox Axis 2 gearbox is of a conventional type. the whole unit must be changed. Attach the crane to the lower arm.Axis 2 Repairs 15.3 Dismantling the lower arm See foldout 2 in the list of spare parts.com The document is for study only. Dismantling the parallel arm. com EMail:cadserv21@hotmail. Dismantling the complete upper arm. Lift the lower arm into position. 13. Dismantling the parallel arm. Tightening torque: Screwed joint of lower arm/gearbox 2.Repairs To assemble: 7. Axis 2 Transfer the damping element and calibration marking to the new lower arm.if tort to your rights. 11.cadfamily.com The document is for study only.5. Fix the lower arm to gearbox 2 using screws <12> and tighten to a torque of 68 Nm. item <12>: 68 Nm Product Manual IRB 2400 www. Calibrate the robot as in chapter 11. grease the bearing seat of the parallel arm in the lower arm. Mount the parallel arm as in chapter 4. Replace the cabling as in chapter 8. 9.we will delete 17 . 12. Replace the upper arm as in chapter 4. To prevent clicking during operation of the robot. 10.please inform us. Cabling and Measuring board. 8.3. Calibration. Attach a hoist to the parallel arm.com The document is for study only. Mount screws <3/135> and tighten. Heat up the bearing <2/20> to 170o C before mounting it on the parallel arm. Mount the tie rod as in chapter 4. Changing the tie rod. item <2/17>: 68 Nm 18 Product Manual IRB 2400 www.4. 8.cadfamily. Dismount the tie rod as in chapter 4.4 Changing the bearing in the lower arm See foldouts 1. 10. 2.com EMail:cadserv21@hotmail. 2 and 3 in the list of spare parts. 9. 12. Mount the other seal ring <2/21> on the parallel arm. Calibrate the robot as in chapter 11. Replace the screws <2/17> and tighten to a torque of 68 Nm. Fit a new bearing <2/20> on the parallel arm.we will delete . 11. Mount seal ring <2/21> on the parallel arm. Mount V-ring <2/19>.if tort to your rights. 6. 4. Unscrew screws <2/17> which hold the parallel arm to gearbox 3 and remove it. Tightening torque: Screwed joint of parallel arm/gearbox 3. 7.please inform us. Calibration. Loosen the screws <3/135> so that the cables can moved a bit. To dismantle: 1.4. Changing the tie rod. Remove the bearing from the parallel arm.Axis 2 Repairs 3. 3. To assemble: 5. Note the reading. N. Mount tool no. which corresponds to a reading on the dial indicator of 0. with help of the tool. Note the position of the motor and the location of the two screws <1/8>. 4.MP3 and R3. Turn the motor shaft a couple of turns.please inform us. 1. To assemble: 6. 1/9> using a torque of 2 Nm.Repairs Axis 3 4 Axis 3 4.MP1 connector. 9. 14. 10.02 mm. Note the position of the motor before removing it. 8.cadfamily. The oil will start to run out. 13.1 Changing the motor for axis 3 See foldouts 1 and 5 in the list of spare parts. Mount the O-ring <1/6>. Pull gently in one direction.FB3.com The document is for study only. (The gear must not turn. tighten screws <1/8.we will delete 19 . The motor and the drive gear constitute one unit. Loosen connectors R3.com EMail:cadserv21@hotmail. 3HAB 7887-1 at the rear of the motor. 7. Install the motor. The tip of the dial indicator must measure on a 50 mm radius from the centre of the motor shaft. Set the gear play to 0. 2. To dismantle: Lock the arm system before dismantling the motor. 3. Loosen the motor by unscrewing <1/8. 5. 12.if tort to your rights.) Product Manual IRB 2400 www. Release the brake by applying 24 VDC to terminals 7(+) and 8 in the R3. Check that the assembly surfaces are clean and the motor unscratched. 1/9>.B. the brake is located in the motor. Place the tip of a dial indicator against the scribed mark on the measuring tool. Remove the connection box by unscrewing <5/137>. Remove the cover of the connection box. 11.13 mm. 2. Tighten screw <1/8.3 Dismantling the parallel arm See foldouts 1. 3.com The document is for study only. forms a complete unit. The gearbox is not normally serviced or adjusted. then the whole unit must be changed.we will delete .4. 2 and 3 in the list of spare parts. 19. Tightening torque: The motor fixing screws. Loosen the screws <3/135> so that the cables can moved a bit. 2 or 3.13 mm. Then gently knock in the other direction and note the reading. To dismantle: 1. To assemble: 4. Changing the tie rod.2.com EMail:[email protected] mm which corresponds to a reading on the dial indicator of 0. Calibration.2 Changing the gearbox Axis 3 gearbox is of a conventional type. Calibrate the robot as specified in chapter 11. Mount V-ring <2/19>. item 8. 9: 15 Nm 4. and together with the gearboxes for axes 1 and 3. 16. The difference in readings = gear play. 17. 18. Fill with oil. Dismount the tie rod as in chapter 4. To dismantle: See chapter 2.if tort to your rights. Note: If there is reason to change a gearbox on any of the axes 1. See chapter 10. Oil change in gearboxes. 4.cadfamily.please inform us. The gear play should be 0. Unscrew screws <2/17> which fix the parallel arm to gearbox 3. Connect the cabling. 20 Product Manual IRB 2400 www. 1/9> with a torque of 15 Nm.Axis 3 Repairs 15. Remove the bearing and sealings from the parallel arm. Changing the gearbox. manufactured with high precision. Product Manual IRB 2400 www. Mount the tie rod on the manipulator using tool 3HAB 6331-1. 8/50> and seals <35. 10. 3.com EMail:cadserv21@hotmail. Replace the screws <2/17> and tighten to a torque of 68 Nm.4 Changing the tie rod See foldouts 1 and 8 in the list of spare parts. 9. See foldout 1. 2. Mount the other seal ring <2/21> on the parallel arm. Changing the tie rod. Make sure you replace the rod the correct way up. Use a puller to pull out the tie rod <8/43>. Insert a screw in the centre. Fit a new bearing <2/20> to the parallel arm. Use tool 3HAB 6324-1.Repairs 5. Tightening torque: Screwed joint of parallel arm/gearbox 3. 8/49> with Loctite 242. Calibration. 8. 5.com The document is for study only. Calibrate the robot as in chapter 11. 6. 11. Mount new bearings <8/44> and seals <8/48.cadfamily.we will delete 21 . 1. 8. to be used as a support. Move the mechanical stop. Axis 3 Heat up the bearing <2/20> to 170o C before mounting it on the parallel arm. To dismantle: Lock the upper arm in a horizontal position with the help of a crane or similar. Mount washers <33. 8/49> and lock screws <34. Mount the tie rod as in chapter 4. 8/48>. To assemble: 7. 4. Mount seal ring <2/21> on the parallel arm. Remove washers <33. 9. 6. 7. 10. Unscrew screws <34> and <8/49>. item <2/17>: 68 Nm 4.please inform us. Change the bearings <8/44> and seals <8/45>. 8/45>.4. Mount screws <3/135> and tighten.if tort to your rights. 15. 17. 13. before the Loctite starts to harden. Install shaft spindles <1/55> (both sides). Use tool 3HAB 9009-1. Loosen the connectors of the motors of axes 4. 4. Mount sealings <8/41> in the upper arm. Unscrew the nut again.com The document is for study only. 14. Tighten the KM-nut with a torque of 35 Nm. 12.if tort to your rights. 3HAB 6464-1. Pull out the shaft. 5 and 6. To assemble: 8. To dismantle: Attach a crane to the upper arm.cadfamily. 6. 9. Raise the upper arm into the assembly position. 3. Remove the covers <1/57>. Apply Loctite 242 on the KM-nuts. 11.Axis 3 Repairs 4. Tighten the KM-nut on the left side first (robot seen from behind) so that the bearing comes against the collar. Tighten the KM-nut on the right side. 2. The following procedure must be performed within 10 minutes. Disconnect the connection box from the motors. Use tool no.5 Dismantling the complete upper arm See foldouts 1 and 8 in the list of spare parts. Mount the inner ring of the bearings <8/42> on shafts <1/55>. right). 18.we will delete .please inform us. Changing the tie rod. 22 Product Manual IRB 2400 www. 5.com EMail:cadserv21@hotmail. 7. Remove screws <1/56>. 1. Undo the KM nuts <1/54>. Unscrew the KM-nut and then tighten with a torque of 35 Nm.4. 16. Mark the shafts (left. Dismount the tie rod as in chapter 4. Insert screws <1/56> and tighten with torque 90 Nm. until there is no play. 10. move the upper arm up and down at the same time. 22.Repairs 19. Tightening torque: KM nut. item <1/54>: 35 Nm Product Manual IRB 2400 www. 23. 21. Calibration. plate for axis 3.com EMail:cadserv21@hotmail. Mount the covers <1/57>.4.com The document is for study only. 20. Mount the sync. Changing the tie rod. Mount the tie rod as in chapter 4.we will delete 23 .please inform us.if tort to your rights. Reconnect the connection boxes and the cabling.cadfamily. Calibrate the robot as in chapter 11. so that the air can go out. Axis 3 Push in a strap from the other under the sealing. please inform us.we will delete .com EMail:[email protected] tort to your rights.Axis 3 Repairs 24 Product Manual IRB 2400 www.com The document is for study only. 1.6) and R3. Product Manual IRB 2400 www. 10. 2.MP(4.5. See chapter 10. To assemble: Valid for axis 4 7.cadfamily. 3. Drain the oil in the gearbox. Loosen the motor by unscrewing <7/28>.Repairs Axes 4-6 (IRB 2400/10/16) 5 Axes 4-6 (IRB 2400/10/16) 5. Push the motor radially so that the play becomes minimal within one motor turn.5.MP4 connector. 8.com The document is for study only. Mount O-ring <7/27>.we will delete 25 . Note the position of the motor before removing it. Remove the connection box by unscrewing <7/58>.please inform us.FB(4. 4. Oil change in gearboxes. Seek up the smallest play by turning the motor shaft 6 turns and thereby find the area with the smallest play within this range. Lock the arm system before dismantling the motor. Open plug <33> or position the upper arm vertical. The motor and the drive gear constitute one unit. Mount tool no. Loosen connectors R3. 12.1 Replacing the motor See foldouts 7 and 8 in the list of spare parts. Fill with oil if drained. 6.com EMail:cadserv21@hotmail. Release the brake in motor for axis 4 by applying 24 VDC to terminals 7(+) and 8 on the R3. 13.if tort to your rights. Connect the cabling. To dismantle: Valid for axes 4-6. the brake is located in the motor. 9. 14. Remove the cover of the connection box. 11.6). without the gear “chewing”. Check that the assembly surfaces are clean and the motor unscratched. 5. 3HAB 7887-1 at the rear of the motor. Calibration. and thereby find the area where the play for motor 6 becomes smallest.cadfamily. Fill with oil if drained. Mount tool no. 16. Find the smallest play for axis 6 within this area. totally 3 turns. 3HAB 7887-1 at the rear of the motor. 12. Mount O-ring <7/27>. 13. Fill with oil if drained. Connect the cabling. Turn the motor for axis 5 one full turn at the time. Push the motor radially so that the play becomes minimal within one motor turn. totally one whole turn. 14. 14. 8. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°.com EMail:cadserv21@hotmail. Mount tool no. and thereby find the area where the play for motor 5 becomes smallest. Turn the motor for axis 6 one full turn at a time. 12. totally 5 turns. Repairs Check that the assembly surfaces are clean and the motor unscratched. 9. 11.Axes 4-6 (IRB 2400/10/16) 15. Mount O-ring <7/27>. Calibrate the robot as specified in chapter 11. 3HAB 7887-1 at the rear of the motor. 15. 26 Product Manual IRB 2400 www. Connect the cabling. without the gear “chewing”. Push the motor radially so that the play becomes minimal within one motor turn. See chapter 10. 15.we will delete . Valid for axis 5 7. totally one whole turn. 13. Oil change in gearboxes. Calibrate the robot as specified in chapter 11. Oil change in gearboxes. 10. 8. without the gear “chewing”.please inform us.if tort to your rights. Valid for axis 6 7. Seek up the smallest play by turning the outgoing shaft for axis 4 in intervals of 90°.com The document is for study only. See chapter 10. Calibration. Calibration. Calibrate the robot as specified in chapter 11. Turn the motor for axis 5 one full turn at a time. 11. Find the smallest play for axis 6 within this area. Find where the smallest play is within this area. 10. Check that the assembly surfaces are clean and the motor unscratched. 9. totally 5 turns. ABB Robotics recommends its customers to carry out only the following servicing and repair work on the wrist. To dismantle: 1. Mount O-ring <19> with grease on the wrist.we will delete 27 . Instead it should be sent to ABB Flexible Automation for service etc.2 Dismounting the wrist The wrist.Repairs Tightening torque: The motor’s fixing screws. 7. Upper arm seen from the front Gears on drive shaft unit axes 5 and 6 Gears on the wrist Figure 1 Adjusting the play for the wrist. Release the brakes on axes 5 and 6 (one at the time) and mount tool 3HAB 7887-1 at the rear of the motor. item 28: 11 Nm Axes 4-6 (IRB 2400/10/16) 5. It is a replacement unit of complex design and should not normally be serviced on-site. Mount the wrist. 2. Remove the oil plugs on the wrist and drain it as described in chapter 10. is a complete unit comprising drive units and gearboxes.cadfamily. See foldout 7 in the list of spare parts.com The document is for study only.please inform us. 5. Replacing the motor.1. 4. which includes axes 5 and 6. Do not tighten the screws. Run the upper arm to a vertical position. To assemble: 3.if tort to your rights. Undo screws <20> and remove the wrist. Oil change in gearboxes. Oil change in gearboxes. see chapter 5.com EMail:cadserv21@hotmail. to locate the smallest play in the same way as for adjustment of play when changing motors for axes 5 and 6. 6. • Change the oil as shown in the table in chapter 10. Push the wrist. as shown in Figure 1. wrist side pointing upwards. Product Manual IRB 2400 www. 5.we will delete . Tightening torque: Screwed joint of wrist/tubular shaft. Undo screws <32> and remove the stop for axis 4. 9. Calibrate the robot as in chapter 11. item <20>: 17 Nm 5.com The document is for study only. To dismantle: 1.3 Dismounting the mechanical stop for axis 4 See foldout 7 in the list of spare parts.com EMail:cadserv21@hotmail. To assemble: 3. 4.Axes 4-6 (IRB 2400/10/16) 8. Repairs 10. Tighten screws <20> with washer <21> to a torque of 17 Nm. item <32>: 15 Nm 28 Product Manual IRB 2400 www. Oil change in gearboxes.cadfamily. See chapter 10. 2. Mount damper <30>. Rotate axis 4 so that the damper <30> becomes visible. Fill with oil. 11.please inform us.if tort to your rights. Mount stop for axis 4 with screws <32> and tighten with a torque of 15 Nm. Check the play by moving axes 5 and 6 by hand. and pull it out. Calibration. Tightening torque: Screwed joint of stop/arm housing. Put sealing compound Loctite 574 on the stop. Check that the assembly surfaces are clean and the motor unscratched. Put O-ring <9/18> on the motor.1 Changing the motor See foldouts 9 and 10 in the list of spare parts.com The document is for study only.MP4 and R3.please inform us. 4. Loosen the motor by unscrewing <9/17>.MP4 connector. Note the position of the motor 10. 15. Connect the cabling. 11. apply Loctite 242 and tighten to a torque of 4. Loosen connectors R3. To assemble: 6.if tort to your rights. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft.we will delete 29 .1. To dismantle: 1.FB4. Remove the connection box by unscrewing <10/29>.1 Axis 4 6. Note the position of the motor before removing it. 9. 8. Calibrate the robot as in 11. 2. Calibration. apply 24 V DC to terminals 7 and 8 on the R3. Product Manual IRB 2400 www. Install the motor. 5. 3. Unscrew one screw at a time. The motor and the drive gear constitute one unit. 13. 7. Remove the cover of the motor. 14.Repairs Axes 4-6 (IRB 2400L) 6 Axes 4-6 (IRB 2400L) 6.cadfamily. Make sure there is a small clearance. Release the brake. 12. Adjust the position of the motor in relation to the drive in the gearbox.com EMail:[email protected] Nm ±10%. Position the arm system in such a way that the motor of axis 4 points upwards. tighten screws <9/17> to a torque of approximately 2 Nm. Undo screws <25>. item <9/17>: 4.com The document is for study only. Grease the seating of the arm housing to provide radial sealing. 9> under the drive gear. Then tighten screws <25> to a torque of 20 Nm ±10%. 3. Screw in screws <25> together with their washers <24> and pull the gear down. Do not forget to insert shims <7.1. 30 Product Manual IRB 2400 www.2. 15. Changing the motor. N. 2. 10. Undo screws <12> fixing the large drive gear <10> and dismantle it. 7.B.B.if tort to your rights. The Wrist and Axes 5 and 6. Dismantle the wrist as in 6.2. gear belts or motors. 5. Repairs To assemble: 8.1.1. Tighten screws <25> to a torque of approximately 5 Nm.Axes 4-6 (IRB 2400L) Tightening torque: The motor’s fixing screws. Dismantle the drive mechanism as in 6. Push the gear unit down into the arm housing. 13. To dismantle: 1.3 Nm ±10%.2 Changing the intermediate gear including sealing See foldout 9 in the list of spare parts. 14.please inform us.com EMail:cadserv21@hotmail. 9. 8. Dismantle the motor of axis 4 as in 6.1 Nm ±10% Tool: Crank tool for checking the play: 3HAB 1201-1 6.2. 6. Check the clearance in relation to the tightening torque.we will delete . 12. Mount the drive gear <10> using screws <12> and tighten to a torque of 8. 11. Push the intermediate gear out of the arm housing. Remove the cover <28>.cadfamily. N. Put the shims in a safe place. 4. Changing the drive shaft unit. Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in relation to the highest point of the large drive gear. 2. Unscrew screws <12> that hold the large drive gear <10> and then dismantle it. 2. 23.1. Replace the cover <28> using screws <29>. Use a drop of Loctite 242. Changing the drive shaft unit. Dismantle the drive mechanism as in 6. 18.3 Changing the drive gear on the tubular shaft See foldout 9 in the list of spare parts. Install drive mechanism <15> as in 6.we will delete 31 . Apply Loctite 574 as sealing. Position the manipulator so that the tubular shaft points upwards. 20. The Wrist and Axes 5 and 6. Changing the motor.if tort to your rights. Calibration. Install the motor of axis 4 as in 6.B.2. Changing the drive shaft unit.please inform us. 5. To dismantle: 1. Dismantle the motor of axis 4 as in 6. gear belts or motors.2. Fill (30 ml) oil into the gear of axis 4. Remove the cover <28>. 19.1. Tightening torque: Screws for the large drive gear.2. See Maintenance. 21. 3.com EMail:cadserv21@hotmail. Unscrew screws <25> that hold the intermediate gear in place. 22. item <25>: 20 Nm ±10% 6.1. N.3 Nm ±10% Screws for the intermediate gear of axis 4. 17. 4.1. Product Manual IRB 2400 www. Put the shims from under the drive gear in a safe place.Repairs Axes 4-6 (IRB 2400L) 16.1. Changing the motor.com The document is for study only. The Wrist and Axes 5 and 6. item <12>: 8. Dismantle the wrist as in 6.2. Replace the wrist as in 6. 6. gear belts or motors. Clean the surfaces of the armhousing and cover.cadfamily. Calibrate the robot as in 11.2. Adjust the intermediate gear as in 6. Clean the surfaces of the cover.1.1. Do not forget the shims. Lubricate the drive gear with grease (30 g). gear belts or motors. 14.com The document is for study only. 15. Install the drive gear using screws <12> and tighten to a torque of 8.05 mm. 8.com EMail:[email protected] Nm ±10%. Changing the drive shaft unit.2. 10. Calibrate the robot as in 11. Changing the intermediate gear including sealing. Calibration.cadfamily. item <12>: 8. Repairs Figure 2 Measuring the shim thickness of the drive gear of axis 4. 9. Install the motor of axis 4 as in 6. 13. Replace the cover <28> using screws <29>.if tort to your rights. 7. Dismantling the wrist.2. Mount the drive mechanism as in 6. see Figure 2. Mount the wrist as in 6. Changing the motor.1.A + 0.3 Nm ±10% 32 Product Manual IRB 2400 www.B. Apply Loctite 574 as sealing 12.2. Tightening torque: Screws of drive gear. 11. N. Lock by using a drop of Loctite 242. Shim thickness = B .1.we will delete .2.Axes 4-6 (IRB 2400L) To assemble: Shim between drive gear <10> and the rear bearing <4>.please inform us. but should be sent to ABB Flexible Automation to be serviced.3. Push out the tubular shaft.cadfamily. • Change the oil according to the table in the chapter on maintenance.we will delete 33 . comprising drive units and gears. Calibration.3. To assemble: 3. Changing the drive gear on the tubular shaft.please inform us. It is of such a complex design that it is not normally serviced on-site. 4. which includes axes 5 and 6. is a complete unit.com The document is for study only. Push the tube into the housing of the upper arm. Tools: Pressing tool for front bearing: 6896 134-V Pressing tool for rear bearing: 6896 134-JB 6. 6. Calibrate the robot as in Chapter 9. ABB Robotics recommends its customers to carry out only the following servicing and repair work on the wrist. 2.1. Dismantle the drive gear as in 6. Insert the rear bearing <4> using tool 6896 134-JB.1.4 Changing bearings of the tubular shaft See foldout 9 in the list of spare parts.2 The Wrist and Axes 5 and 6 The wrist. Mount the drive gear as in 6.1.if tort to your rights. To dismantle: 1.com EMail:cadserv21@hotmail. Fit a new bearing <4> on the tubular shaft using tool 6896 134-V.Repairs Axes 4-6 (IRB 2400L) 6. Changing the drive gear on the tubular shaft. 5. Product Manual IRB 2400 www. 7. com The document is for study only. Make a note of the motor no. Rotate axes 5 and 6 so that you can see screws <11/9> in the clamping sleeve through the hole. Dismantle the wrist as in section 6.1. Disconnect the clamping sleeve. 4.cadfamily. 5. 11.please inform us.3 Nm ±10% Screwed joint clamping sleeves. 12.2. Calibration. Clean the surface of the tubular shaft. Calibrate the robot as in 11. To dismantle: 1. 8.7 Nm. Replace the plugs. gear belts or motors See foldouts 9 and 11 in the list of spare parts. 3.Axes 4-6 (IRB 2400L) Repairs 6. Undo screws <9/37> and washers <9/13>. item <11/9>: 5.2 Changing the drive shaft unit. to simplify the reconnection.com EMail:[email protected]. 7. Release the brake in axes 5 and 6. 2. 9. 2. To assemble: 6. Dismantling the wrist. Undo screws <9/14>. Apply Loctite 574 all around. To dismantle: 1. Loosen the connection box and disconnect the connectors on the motors of axes 5 and 6.7 Mn ±10% 6. Tightening torque: Screwed joint of wrist/tubular shaft.if tort to your rights. Remove the wrist. Mount the wrist.3 Nm ±10%.2. on the motors. Screw the clamping sleeves together using screws <11/9> to a torque of 5. tighten screws <9/37> to a torque of 8. 3. item <9/37>: 8. Remove the 2 plugs on the rear of the wrist.1 Dismantling the wrist See foldouts 9 and 11 in the list of spare parts. 34 Product Manual IRB 2400 www.we will delete . Mount the cover at the motor side of axis 5-6. 10. 17. 10. Pull out the complete drive mechanism of axes 5 and 6. Use tool 3HAA 7601-050. Dismantling the wrist. 18. in order that they can pass through the tube. 11. Do not forget the nuts on the motors. Push the motors sideways to tighten the belts. 15. 12. Install the belts <11/7>.Repairs 4. 7. It is sufficient to only calibrate axes 5 and 6. if the other axes have been positioned correctly by running the CAL2400 program. Do not forget the rubber damper <9/11>.1 Nm. 13. item <9/14>: 8. To assemble: 9. Mount the wrist according to section 6. Install the motors. 6. N. Undo screw <11/5> and remove the motor plate <11/3> and screw <11/9>. Install the drive mechanism in the tubular shaft.B. Tightening torque: Screwed joint of the drive mechanism. Remove the gear belts. 5.if tort to your rights. Tighten screws <11/5> to a torque of 4. Calibrate the robot as in chapter 11. Calibration.com EMail:[email protected] Nm ±10% Screws holding motors. 8. holding the motors and remove both motors.1. Do not forget to change the resolver offset values on the label under the rear cover on the robot base. Check the tension on the belt.2.we will delete 35 . Mount the plate <11/3> using screws <11/5> and washers <11/6>. Undo screw <11/5> and nuts <11/4>.cadfamily. 14. Place the round post of the tool into the motor pulley and let the cam press to the outer diameter of the large pulley. N.1 Nm ±10% Product Manual IRB 2400 www.3 Nm. Tighten screws <9/14> to a torque of 8. Install the cabling and mount the cover to motors axes 5 and 6. Axes 4-6 (IRB 2400L) Squeeze the drive shafts (<11/1>) together at the tip of the tubular shaft.please inform us.com The document is for study only. 16. item <11/5>: 4.B. Rotate the drive shafts. Remove the appropriate motor. 3.2.if tort to your rights. Mount the plate <3> using screws <5> and washers <6>. Changing the drive shaft unit. Push the motors in sideways to tension the belts. Tool: To adjust the belt tension: 3HAA 7601-050 36 Product Manual IRB 2400 www. 13. Undo screws <5> and nuts <4>. N. Remove plate <6>. 7. Changing the drive shaft unit.Axes 4-6 (IRB 2400L) Repairs 6.com The document is for study only. Install the drive mechanism as in 6. If the driving belt is to be changed. Rotate the drive shafts. 2. gear belts or motors. Dismantling the wrist.2. Dismantle the wrist as in section 6.com EMail:cadserv21@hotmail. 12. Dismantling the wrist. 10. Calibration. 8.2. 4. gear belts or motors. Install the driving belts. Calibrate the robot as in 11.2.1. item <15>: 4.cadfamily. both motors must be removed before plate can be removed.3 Changing the motor or driving belt of axes 5 and 6 See foldout 11 in the list of spare parts.we will delete . Mount the wrist as in section 6.2. Install the motors. To assemble: 6. Tightening torque: Screws for motors and plate.2.1. Check the tension on the belt. 9. 11. Dismantle the drive mechanism as in 6. Tighten screws <15> to a torque of 4.1 Nm. Use tool 3HAA 7601-050. Undo screws <5> and washers <6>.please inform us. Do not forget the nuts of the motors.1 Nm. To dismantle: 1.2. 5.B. com EMail:cadserv21@hotmail. If they are mixed up. The push-button unit <121> is located on the flange plate on the base and is used to quickly and safely release the axis brakes manually.MP on the robot base. The brakes are of electro-mechanical type and are released when voltage is applied. the brake will be released immediately the power is switched on.1 General description See foldout 4. +24 V B8 Incorrect connections can cause all brakes to be released simultaneously 2. B8 0 V to C10 0 V C10 NOTE! Be careful not to interchange the 24 V and 0 V pins. Product Manual IRB 2400 www. The brake will function again as soon as the button is released. push the appropriate button and keep it depressed.Repairs Push-button unit for brake release 7 Push-button unit for brake release 7.please inform us. Directly to the cable of the respective brake. This can cause some unexpected robot movements! The push-button unit is equipped with six buttons for controlling the axis brakes.com The document is for study only. To release the brake on a particular axis. Connector R1. When the controller or certain parts of the cabling have been disconnected.MP. damage can be caused to the brake release unit and the system board.if tort to your rights. The connection must be made in accordance with the wiring diagram for the mechanical robot. when this is necessary. The buttons are numbered with the axes numbers. The unit is located underneath a rubber cover in the cover. Note: when power is connected directly to the brake cable. The power is connected as described in one of the following two alternatives: 1. the brakes can be released using a separate 24 VDC power source.cadfamily. It is then also possible to move the arms of the robot manually. when doing various types of work on and around the robot. + 24 V to R1.we will delete 37 . Disconnect the connectors on the cabling to the push-button unit <121>.we will delete . 6. 4.please inform us. Repairs When replacing the push-button unit <121>. Note: the robot must not be in the STANDBY MODE! This applies for all types of cabling work. Refit a new unit in the reverse order. Remove the push-button unit by undoing the screws. 3. 2. Cut the power to the robot by turning off the main switch. 38 Product Manual IRB 2400 www.cadfamily.if tort to your rights. Remove the cover. 5.com The document is for study only. the complete unit should be replaced as follows: 1.com EMail:cadserv21@hotmail. Position the lower arm at one of its end positions and lower the upper arm to its end position.Push-button unit for brake release To dismantle: See foldout 4. Unscrew the serial measuring board <115> using nuts <118>.MP. Assemble in the reverse order. The lower bracket need not to be removed. Remove the board and loosen the contacts. Cut straps. Loosen the serial measurement board. Remove cable straps <3/119>. 4. Remove the flange plate on the base. Loosen covers <3/112> and screws <3/137>. 4. Detach the cable guides <3/109>.we will delete 39 .cadfamily. Loosen the flange plate on the base. 3.Repairs Cabling and Measuring board 8 Cabling and Measuring board 8. 6. 7.com The document is for study only. Remove the cover of the connections boxes. Disconnect the connection boxes in the motors.2 Changing the cabling in axes 1.please inform us. Loosen nuts <5/118>. 5. 8. 2. Note! When working with the serial measurement board it is important that a wrist strap is used. 2.com EMail:[email protected] Changing serial measuring board See foldout 5 in the list of spare parts. 2 and 3 are handled as one unit. Loosen the connectors. To dismantle: 1. to avoid ESD faults.FB1-3. Product Manual IRB 2400 www. Loosen connectors R1.if tort to your rights. The cables to motor axes 1. To dismantle: 1. To assemble: 5. R2. 3.2 and 3 See foldouts 3 and 4 in the list of spare parts. option 04y To dismantle: 1. including customer connector R1. To dismantle: 1. Loosen connectors R2. 4. Loosen nuts <5/118>.MP6. Loosen screws <3/120>. 5 and 6 See foldouts 3 and 4 in the list of spare parts. 5 and 6 and for customer signals are handled as one unit.FB4-6. 8. To assemble: 10.MP4-6 and R2. Loosen screws <3/120> and cable brackets <3/108> between gears 2 and 3 and cut the tie around them. 2. Feed the cabling up through the middle of axis 1. (To reach R2.CP and R2. Loosen the flange plate <3/104>. 5.com The document is for study only.FB4-6. R3FB5 and R3FB6. two M6 + three M8 screws.please inform us. Assemble in the reverse order. 7. Loosen screw <3/137> to remove cable guide <3/111>. Loosen the cable bracket on the lower arm and undo screws <3/116>. The cables to motor axes 4. Feed the cabling and air hose up through axis 1. Assemble in the reverse order. Remove the cover of the motors.4 Changing the signal cabling axis 4. 3.we will delete . Loosen the two plates. 9. Repairs To assemble: 10.) Remove cable straps <3/119>. 8. 40 Product Manual IRB 2400 www.MP5. and the air hose in the base.3 Changing the cabling in axes 4. R3. the serial measurement board can be removed.FB4-6. 9.if tort to your rights.com EMail:cadserv21@hotmail. R3.CS. R1. Loosen the connection box from the motors.Cabling and Measuring board 8. R3.MP4.FB4.cadfamily. Loosen connectors R3. 8. 6. Run axis 4 to its calibration position.com EMail:cadserv21@hotmail. 5. NOTE! If this should happen. Remove dirt and grease from the surface first.cadfamily. see Figure 3. see Figure 4. 9. 3. To assemble: 4.if tort to your rights. 6 7.com The document is for study only. see Figure 4. NOTE! Leave the rear cable holder open (do not tighten). Then fasten the rear (inner) plate with three M8 screws. 8. Fasten the front (outer) plate with two M6 screws. 3 M8 2 M6 Figure 4 Location of screws. Check all the time that the cables are not fully stretched. Slowly rotate axis 4 clockwise to its stop position. Tape Wrist side Figure 3 Location of protection tape. 0 degrees.we will delete 41 . Finish the rotation. This is done by loosening the grey holders and pushing out the cables by hand.Repairs 2. Product Manual IRB 2400 www. stop the rotation and let out more cable from the rear cable holder. Loosen the connectors at the rear of the upper arm. Apply transparent protection tape on the narrow part of the tube shaft. Cabling and Measuring board Loosen the two holders around the tube shaft.please inform us. The length of the cables is now finely adjusted by pushing and pulling the cables through the inner holders. 17. 42 Product Manual IRB 2400 www. 13. 16. 11. Mount the front holder around the tube shaft first.com The document is for study only. Carefully check the behaviour of the cables! They must not be fully stretched. no stretching of the cables should be felt. 12. Connect the connectors at the rear end of the upper arm.please inform us. Move axis 4 from one extreme limit to the other and back again. Tighten the holders by hand.we will delete . see Figure 5.Cabling and Measuring board Repairs 10. Applies to both fixing rings. Figure 5 Mounting the fixing rings on the tube shaft. Let the black plastic hose around the arm go through the foot of the fixing ring. The cables and air hose must not touch any moving parts of the arm.com EMail:cadserv21@hotmail. which are still loose. Connect the air hose.if tort to your rights. Fix the cables and air hose together with cable straps above the motors. When axis 4 is moving. 15. Do not use any tools.cadfamily. 14. The fixing rings must be able to slide smoothly the whole time with no excessive pulling. from entering the system.we will delete 49 . Treat the balancing system as a replacement unit. This closed system also prevents dirt etc. When the robot is in the calibration position. Move the manipulator to the calibration position.cadfamily. Make a note of the pressure. The cylinder is charged with nitrogen.if tort to your rights.1 General description See foldout 2. The balancing system should not be opened or tampered with. it is essential that the gas spring is pressurised correctly. Product Manual IRB 2400 www. To obtain maximum use of the robot’s excellent performance.com EMail:cadserv21@hotmail. Check that the brakes are on.2 Dismounting the balancing spring To dismantle: See foldout 2 and 6 in the list of spare parts. 1. i.Repairs Balancing system 9 Balancing system 9. before releasing the pressure in the cylinder using the charging device no. 3HAB 5880-1.e. 3. The purpose of the balancing system is to give balance to the lower arm. Clean around the safety screw.com The document is for study only.please inform us. replace it as a complete unit when necessary. (oC) 10 20 30 40 Floor mounted 155 160 165 171 Inverted 164 170 176 182 IRB 2400L Pressure (± 3 bar) Floor mounted 145 150 155 160 Inverted 164 170 176 182 9. 2. (all axes 0o) the pressure should be as follows: IRB 2400/10/16 Pressure (± 3 bar) Temp. 16. When the gas start to stream out. Remove the safety screw. Attach the screw fitting on the regulator to the balancing spring using the larger of the double handwheels. Note! The joint must not be tight.5 mm / min >0 mm. 20.com EMail:[email protected] the balancing spring in position at the lower end.if tort to your rights. When the gas stream start to reduce.Knock shaft <25> gently into position with a plastic hammer. close the valve with the handwheel and the balancing spring valve. When emptying the gas spring. Lock with Loctite 242. Note.Place the balancing spring piston rod attachment in position in the lower arm. open the valve by turning the small hand wheel carefully. When the gas has been discharged. Remove the regulator housing and replace the safety screw. The valve on the gas spring is easily damaged if the gas spring is emptied to quickly.we will delete . 18. 13 . the valve can be opened a little more.please inform us.Balancing system Repairs 4. 15. 10.Hold the balancing spring and push out the axis to the right.cadfamily. It should take at least 2 minutes to empty the gas spring.Remove the shaft <25> in the lower end. Release the gas with the handwheel on the side. 50 Product Manual IRB 2400 www.com The document is for study only. 19.Mount 3 plastic washers <28> on the left side.Mount screw <26> and washer <27>.Remove screw <31> in the upper end. 11. Connect the hose on the charging device to the nitrogen tube. Warning! Large quantities of nitrogen gas in a small room can be toxic! Warning! Direct contact with escaping gas can cause frost injuries! 7.Remove screw <26> and washer <27>.Mount screw <31> and tighten with torque of 68 Nm. To assemble: 14. open it just a little more. Take care of the washers <28>. that the smaller of the double handwheels should be turned anticlockwise. 17. 8. 1. it must always be a small play in it. 6. Open the balancing spring valve carefully by screwing the smaller of the double handwheels inwards and clockwise. 12. 5. repeat this every time the gas stream start to reduce. Note! Don’t forget washer <29>. 9.Adjust with plastic washers on the other side so that the play is max. if tort to your rights. 27.com The document is for study only. Then close the spring valve by turning the smaller of the two double handwheels anticlockwise. Let the valve remain in place (art.Open the spring valve by screwing the smaller of the double handwheels inwards (do not screw to the bottom).Attach the regulator housing to the balancing spring using the larger of the double handwheels. 24.cadfamily.It is important that the bearings on the rear and especially the front side of the gas spring are greased correctly: Mount a greasing nipple and press in grease Optimol PDO in the right hole until grease comes up through the left hole without air bubbles. 28.Repairs Balancing system 21. If there is any leakage. Close these two valves and remove the regulator housing. 3HAC 0640-1).charge very slowly with gas to the pressure specified in the table above using the valve. replace the valve.please inform us.Empty the gas from the regulator and hose by opening the handwheel on the side and the gas valve on the hose.Close the nitrogen tube. 22. 23. see Figure 7 Grease shall be pressed out until no air bubbles are coming out Grease shall be pressed out until no air bubble are coming out Grease Optimol PD0 Grease Optimol PDO Grease Optimol PDO Rear and front gas spring bearings Rear and front gas spring bearings Figure 7 Greasing of gas spring bearings. 29.Check that the valve does not leak before fitting the sealing washer and safety screw. 25. Product Manual IRB 2400 www.Check that the gas valve is closed (lever at 90o to hose) before opening the nitrogen tube.com EMail:cadserv21@hotmail. 26. replace the valve.Unscrew the safety screw. The lower arm must be in a vertical position. no. If there is any leakage.we will delete 51 . Lift out the valve using a pair of valve pliers no. Release the pressure in the spring as described in chapter 9. Dismounting the balancing spring.com The document is for study only. 2.please inform us. Fit the new valve (art. 5. Refitting: 4.2.com EMail:cadserv21@hotmail. 3HAC 0640-1). 3.if tort to your rights.3 Changing the valve in the balancing spring Removal: 1. Dismounting the balancing spring. no. 6808 0011-LE.2.Balancing system Repairs 9.cadfamily. 6. Screw in the safety screw. Unscrew the safety screw. 52 Product Manual IRB 2400 www.we will delete . Charge with gas as described in chapter 9. A brake. The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis.570800. resolver and brakes are regarded as one complete unit. operated electromagnetically.com The document is for study only.Repairs Motor units 9 Motor units 9. There are a total of six motors mounted in the manipulator. The brake releases when power is supplied to the electromagnets. The power and signal cables are run to the respective motor from the cable connector points on the manipulator. Product Manual IRB 2400 www. The cables are connected to the motor units by connectors.a brake (built into the motor) . is mounted on the rear end of the motor shaft and a pinion is mounted on its drive end. N. The motor.if tort to your rights.e. The device is installed by the supplier of the motor and should never be removed from the motor.we will delete 43 .a synchronous motor . There is a feedback device mounted on each motor unit.B.cadfamily.1 General Each axis of the manipulator has its own motor unit. i. The motor need never be commutated.a feedback device. a replacement unit.please inform us.com EMail:cadserv21@hotmail. comprising: . The commutation value of the motors is: 1. if tort to your rights.com The document is for study only.we will delete .Motor units Repairs 44 Product Manual IRB 2400 www.please inform us.com EMail:[email protected]. 5 litres (0. 1171 2016-604 corresponds to: BP: Esso: Optimol: Texaco: Energol GR-XP 320 Spartan EP 320 Optigear 320 Meropa 320 Castrol: Klüber: Shell: Alpha SP 320 Lamora 320 Omala Oil 320 30 ml (0.Repairs Oil change in gearboxes 10 Oil change in gearboxes 10.032 US gallon) Volume of gearbox 4: Volume of wrist Product Manual IRB 2400 www.1 US gallon) 10.if tort to your rights.1 Oil in gearboxes 1-3 (IRB 2400L/10/16) ABB article no.2 US gallon) total 10.3 US gallon) 3.5 litres (1.com The document is for study only. 3HAC 0860-1 corresponds to: Optimol: Optigear BM 100 Volume of gearbox 4: Volume of gearboxes 5 and 6: 1.8 litres (0.we will delete 45 .4 litres (1.4 US gallon) 0.7 US gallon) 4.cadfamily. 1171 2016-604 corresponds to: BP: Esso: Optimol: Texaco: Energol GR-XP 320 Spartan EP 320 Optigear BM 320 Meropa 320 Castrol: Klüber: Shell: Alpha SP 320 Lamora 320 Omala Oil 320 Volume of gearbox 1: Volume of gearboxes 2: Volume of gearboxes 3: 6.com EMail:[email protected] inform us.3 Oil in gearboxes 4-6 (IRB 2400L) ABB article no.8 litres (1.008 US gallon) 120 ml (0.2 Oil in gearboxes 4-6 (IRB 2400/10/16) ABB’s article no. axes 5-6 (IRB 2400L) The magnetic oil plugs in gearboxes 5 and 6 (see Figure 7) should be cleaned when filling oil. 10. and the upper arm at least 45o upwards.cadfamily.if tort to your rights.we will delete . 10.please inform us.com EMail:cadserv21@hotmail. axes 4-6 (IRB 2400/10/16) The magnetic oil plugs in gearboxes 4. New oil is refilled as follows: • Run the upper arm in a vertical position (rear end upwards). 5 and 6 (see Figure 6) should be cleaned when filling oil.5 Oil plugs.Oil change in gearboxes Repairs 10. Oil plug axis 4 Oil plug axes 5 and 6 Figure 6 Location of oil plugs. • The oil is filled through the plug hole.4 Oil plugs.6 Changing and checking the oil in gearbox 4 (IRB 2400/10/16) Drain the gearbox: • Move the arms backwards. Oil plug axes 5 and 6 Figure 7 Location of oil plugs.com The document is for study only. • The oil is drained through the lower drain plug hole at the rear of the upper arm. 46 Product Manual IRB 2400 www. Product Manual IRB 2400 www. 10.cadfamily. Changing the motor. Volume: • 1.we will delete 47 . 32 mm and max.8 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400/10/16) Draining the gearbox: • Run the upper arm to a horizontal position and turn axis 4 to the calibration position.Repairs Oil level: Floor and suspended mounting: Oil change in gearboxes . • Turn axis 4 through 90o so that the oil plug on the side of the wrist is pointing downwards. • Let the remaining oil run out through the hole on the tilt housing (axis 5). • Then turn axis 4 another 90o. • Run the robot until the upper arm is pointing downward.With the upper arm in a vertical position (rear end upwards) must the oil level be min. • NOTE! If the robot is mounted in suspension. • Put the oil plugs back in the wrist. see chapter 6. New oil is refilled as follows: • Run the robot until the upper arm is pointing upward. New oil is refilled as follows: • Run the upper arm to a horizontal position and turn axis 4 to the calibration position.if tort to your rights. Volume: • 30 ml (0. • The oil is filled through the motor hole. 25 mm from the edge of the upper hole. the wrist should be turned 180o.4 US gallon) 10.008 US gallon). • Fill oil in the hole located on the tilt housing (axis 5) until the oil reaches up to the hole located on the side of the wrist (see Figure 6).7 Changing and checking the oil in gearbox 4 (IRB 2400L) Drain the gearbox: • Dismantle the motor axis 4. • Remove the oil plugs in the wrist (see Figure 6).com EMail:[email protected] The document is for study only.please inform us.5 litre (0. Volume: (IRB 2400/ 10/16) • Oil volume for axes 5 and 6 is 0.12 litre (0.if tort to your rights.we will delete . New oil is refilled as follows (IRB 2400L): • Run the upper arm 30° upwards. Oil level (IRB 2400L) • Run the upper arm 30° upwards.com EMail:[email protected] US gallon). • Do not fill oil through the rear two holes. 48 Product Manual IRB 2400 www. Volume (IRB 2400L): • Oil volume for axes 5 and 6 is 0. • The oil should be level with the edge of the oil hole on the side.Oil change in gearboxes Oil level: • Run the robot to the calibration position.8 litres (0. Repairs 10.cadfamily. • The oil is filled through one of the op en front oil plugs.03 US gallon).9 Changing and checking the oil in gearboxes 5 and 6 (IRB 2400L) Draining the gearbox (IRB 2400L): • Move the upper arm downwards.com The document is for study only. Both plugs must be off.please inform us. • The oil should be level with the edges of the oil hole. Remove one of the oil plugs in the wrist (turn axis 6). 3 .6.3) if the contents of the revolution counter memory are lost. as shown in Figure 19. The measurement system needs to be carefully calibrated (as in 11. 4.the signal between the resolver and measurement board is interrupted.if tort to your rights. Choose Service from the dialog box that appears on the display.4 .5 . window key (see Figure 8).a resolver error occurs . Calibrate all the axes as described below.we will delete 49 . The memory may be lost if: .please inform us. Move the robot to the calibration position.1 General The robot measurement system consists of one feedback unit for each axis and a measurement board which keeps track of the current robot position.Repairs Calibration 11 Calibration 11. Product Manual IRB 2400 www.2 Adjustment procedure using calibration equipment (fine calibration) The axes are calibrated in numerical order. Press the Misc. corresponding to the calibration marks.com EMail:cadserv21@hotmail. 11. 3.cadfamily. window key. 7 4 1 1 2 8 5 2 0 9 6 3 P1 P2 P3 Figure 8 The Misc.part of the manipulator that affects the calibration position is replaced. The system needs to be coarsely calibrated (as in 11. i.the battery is discharged .e. The measurement board memory is battery-backed. 2.com The document is for study only. 1 . 1. Resolver values change when any .2 .2) if any of the resolver values change. . Calibration! Robot To calibrate. File Edit View Calib Service Calibration Mech Unit Robot Status 1(4) Not Calibrated Figure 9 The window shows whether or not the robot system units are calibrated. 7. Press Enter .com EMail:cadserv21@hotmail. Choose Calib: Calibrate and the window shown in Figure 10 will appear.Not calibrated One (or more) of the axes is NOT fine-calibrated. 50 Product Manual IRB 2400 www. 6.Synchronized All axes are calibrated and their positions are known.Not updated Rev. . Axis X X 1 2 3 4 5 6 Status Not Fine Calibrated Not Fine Calibrated Fine Calibrated Fine Calibrated Not Fine Calibrated Not Fine Calibrated 1(6) X X Incl All Cancel OK Figure 10 The dialog box used to calibrate the manipulator. Repairs Choose View: Calibration.we will delete .please inform us. . If there is more than one unit. The unit is ready for use. include axes and press OK. Counter All axes are fine-calibrated but the counter on one (or more) of the axes is NOT updated. The window shown in Figure 9 appears. Therefore.2.Calibration 5.3.if tort to your rights. this axis or axes must be updated as described in 11. Therefore.com The document is for study only. The calibration status can be any of the following: .cadfamily. this axis or axes must be fine-calibrated as described in 11. select the desired unit in the window in Figure 9. The calibration for all marked axes will be changed. 12. The robot is now roughly calibrated.com EMail:[email protected] tort to your rights. Guide pin Tool no. 3HAB 8064-1 Figure 12 Calibration of axis 1. The window shown in Figure 11 appears. Remove the protective plate from the reference surface on the manipulator base.Repairs 8. 11.cadfamily. An alert box is displayed during the calibration. Calibration Press the function key All to select all axes.please inform us. Calibration! Robot . OK to continue? Cancel OK Figure 11 The dialog box used to start the calibration... Otherwise. see Figure 12.. Start the calibration by pressing OK. if all axes are to be calibrated. The Status window appears when the fine calibration is complete.com The document is for study only.. It cannot be undone... 10.. select the desired axis and press the function key Incl (the selected axis is marked with an x). Attach the calibration tool for axis 1 on the guide pin underneath the gearbox. The revolution counters are always updated at the same time as the calibration is performed.WARNING . 9.we will delete 51 . Confirm your choice by pressing OK. Product Manual IRB 2400 www. 16. 26. 0±16 increments. Dont use synchronous adapter on IRB 2400L.please inform us. Select the Program window and open the file CAL2410 on the Controller Parameter disk. 28. 3HAB 7981-1 + pin on the turning disc. Update axis 3. Then move the manipulator so that the pin in the tool can be located in the guide hole in the base.com EMail:cadserv21@hotmail. 22.we will delete . 18. Calibrate the sensors for a new direction. Remove the sensors.Calibration Repairs 13. Level sensors 0000 Reference plane Calibrating sensors for axes 2. as described above. Fit the angle shelf no. for axis 2. Remove the calibration tool for axis 1. 15. 23. 21. Run the program and select Calib: Cal3. 6808 0011-LP on the lower arm. before starting calibration. Adjust the angle of the shelf. NOTE! Do not tighten the screw. See Figure 13. Update axis 2 as described above.if tort to your rights. The sensors must be calibrated every time they are used for a new direction. Position the sensors as shown Figure 14. Fit the angle shelf no. adapter no. Remove the sensors. Put the sensors on the shelf and jog the robot to the calibration position. as described above.4 mm/m). Run the manipulator so that the instrument shows 0 ±16 increments (0. 6808 0011-GM on the foot. 25. 14.cadfamily. The robot will now move itself to the position for calibration of axis 3. Run the calibration program 4A on the system diskette. 3 and 5 Calibrating sensors for axes 4 and 6 Figure 13 Calibrating the sensors. 27. Update axis 1 only.com The document is for study only. Release the brakes and move the manipulator manually and fix the tool to the base with the screw. See Figure 14. Fit the reference plane no. See Figure 13. using the reference plane surface. 6808 0011-GU + sync. 20. 19. with the help of the sensors. 17. Calibrate the sensors against each other. 24. 52 Product Manual IRB 2400 www. Run the calibration program 4B. 0 ±32 increments.Repairs Calibration 29.com The document is for study only. Adjust axis 6.please inform us. Change the values on the label. See Figure 14. 35. Calibrate the sensors for a new direction. 0 ±32 increments. 36. 41. See Figure 13. See Figure 13. Update axis 6 as described above. Save system parameters on a floppy disk. Update axis 5 as described above. 40.we will delete 53 . Product Manual IRB 2400 www. 32. 31. located underneath the flange plate on the base (see Figure 14). Run axis 4 to the correct position as indicated by the instrument. Update axis 4 as described above. The robot will now be standing in the correct position. 37. 39.com EMail:cadserv21@hotmail. Update axis 4 as described above.cadfamily. Remove the sensors. 34. Calibrate the sensors for a new direction. 0 ±32 increments.if tort to your rights. 38. 33. See Figure 14. Put the sensors on the shelf and run the robot so that axis 5 comes to the correct calibration position. 30. Calibration plate and calibration marks 42. 3 and 5 Figure 14 Calibration directions. Check the calibration position as specified in 11. 54 Product Manual IRB 2400 www. 2.cadfamily. see Figure 19.please inform us.we will delete .4. The calibration positions for axes 1. 4 and 6 are marked using a punch mark tool. 43. 3.com The document is for study only.com EMail:[email protected] tort to your rights.Calibration Repairs Axis 2 View from above Flange plate Axis 4 Axis 3 Upper arm seen from above Axis 6 Axes 4 and 6 Axis 5 Axes 2. B. a message may be displayed telling you that the manipulator is not synchronised. this should be done according to 11.2. It takes 36 hours in Power On mode without any power interruption to recharge the battery unit.when the battery unit is discharged .when there has been a resolver error .cadfamily. Product Manual IRB 2400 www.com The document is for study only. See Figure 19. the revolution counter of the manipulator must be updated using the calibration marks on the manipulator. 7 4 1 1 2 8 5 2 0 9 6 3 P1 P2 P3 Figure 15 The Misc. manually move the robot so that the calibration marks lie within the tolerance zone (see Figure 19). window key (see Figure 15).! Axes 5 and 6 must be positioned together. The message appears in the form of an error code on the teach pendant.when the signal between the resolver and the measuring system board has been interrupted .please inform us.3 Setting the calibration marks on the manipulator When starting up a new robot. Examples of when the revolution counter must be updated: .Repairs Calibration 11.we will delete 55 . If you receive such a message.when one of the manipulator axes has been manually moved without the controller being connected. N. Press the Misc.com EMail:cadserv21@hotmail. Press the enabling device on the teach pendant and. window key from which the Service window can be chosen. WARNING Working in the robot work cell is dangerous. using the joystick. When all axes have been positioned as above. the values of the revolution counter can be stored by entering the following commands on the teach pendant: 1.if tort to your rights. If the resolver values must be calibrated. select the desired axis and press the function key Incl (the selected axis is marked with an x).com EMail:cadserv21@hotmail. Otherwise. Counter X X Rev. Rev. 5. The window shown in Figure 16 appears. Counter Update. Select Service in the dialog box shown on the display. choose View: Calibration. Counter Rev.please inform us.if tort to your rights.we will delete . include axes and press OK. Then.cadfamily. if all axes are to be updated. Repairs 4. Select the desired unit in the window. 3. The window shown in Figure 17 appears. Press the function key All to select all axes. 56 Product Manual IRB 2400 www. Counter Updating! Robot To update. Press Enter . File Edit View Calib Service Calibration Mech Unit Robot Status 1(4) Unsynchronized Figure 16 This window shows whether or not the robot system units are calibrated.com The document is for study only. Choose Calib: Rev. Counter Rev. 6. Counter Incl All Cancel OK Figure 17 The dialog box used to select the axes for which the revolution counter must be updated. as in Figure 16. Axis X X 1 2 3 4 5 6 Not updated Not updated Calibrated Calibrated Not updated Not updated Status 1(6) Rev.Calibration 2. cadfamily.4. Product Manual IRB 2400 www. Incorrect updating can damage the robot system or injure someone. A window similar to the one in Figure 18 appears. 9.we will delete 57 . Start the update by pressing OK. 10.com The document is for study only. If a revolution counter is incorrectly updated. OK to continue? Cancel OK Figure 18 The dialog box used to start updating the revolution counter.Repairs Calibration 7. Check the calibration as described in 11. Save system parametrs on a floppy disk. it will cause incorrect positioning. Thus. Counter for all marked axes will be changed. check the calibration very carefully after each update. Confirm by pressing OK.if tort to your rights. Rev. 8. Counter Updating! Robot The Rev.please inform us.com EMail:cadserv21@hotmail. It cannot be undone. com EMail:cadserv21@hotmail. axis 1 3HAB 8223-1 Punch. axis 2 3HAB 8223-1 2 markings Punch.please inform us.if tort to your rights. axis 1 3HAB 8223-1 IRB 2400L Punch.we will delete .cadfamily. axis 1 3HAB 8184-1 Punch. 58 Product Manual IRB 2400 www. axis 3 3HAB 8223-1 Punch. axis 1 3HAB 8223-1 Punch. axis 6 3HAB 8184-1 Punch.Calibration Repairs IRB 2400/10 IRB 2400/16 Punch. axis 4 3HAB 8223-1 Punch. axis 2 3HAB 8223-1 2 markings Figure 19 Calibration marks on the manipulator.com The document is for study only. axis 1 3HAB 8223-1 Punch. follow intructions displayed on the teach pendant. Cal pos 1 Normal 0 2 Hanging .if tort to your rights.1. Check that the calibration marks for each axis are at the same level.com The document is for study only. Check that the calibration marks for each axis are at the same level. If they are not. see Figure 20.570796 3 . Controller Parameters: Run the program \ SERVICE \ CALIBRAT \ CAL 1400 (or 1400H) on the diskette. Using the Jogging window on the teach pendant: Open the Jogging window and choose running axis-by-axis.1.we will delete 59 . Cal pos 1 Normal 0 0 2 Normal 0 3 Axis Calibration prog.5 Alternative calibration positions The robot must have been calibrated with calibration equipment at calibration position 0 for all axes (the robot is delivered with calibration position 0).570796 Figure 20 Calibration positions Product Manual IRB 2400 www. both are described below. 11.com EMail:cadserv21@hotmail. see Figure 19.4 Checking the calibration position There are two ways to check the calibration position.Repairs Calibration 11. If they are not. Using the diskette. Axis Calibration prog. move the robot so that the read-out of the positions is equal to zero. the setting of the revolution counters must be repeated.cadfamily. Using the joystick. before it can be calibrated in one of the alternative positions. see Figure 19.please inform us. the setting of the revolution counters must be repeated. switch to MOTORS OFF. When the robot stops. 1.cadfamily. 2. 3. • Calib: Calibrate. Restart the robot by selecting File: Restart. see Figure 20. • Do the same for axis 3. located under the cover on the back of the foot.please inform us. Change to the new calibration position on the axes that have been changed. 6.com The document is for study only. The angle is in radians. Run the calibration program again and select the desired calibration position. Change to the new calibration offset on the label.we will delete . • Select axis 1. The new calibration offset values can be found as follows: • Select the window SYSTEM PARAMETERS. • Manipulator • Types: Motor. 8. Run the calibration program CAL2410 on the Controller Parameter disk. 4.post Normal + Normal position. Save the system parameters on a floppy disk 60 Product Manual IRB 2400 www. Select Cal. 7.if tort to your rights. • Change Cal pos to the value showed in Figure 20. an alternative calibration position can be set before installation. • View: Calibration. as follows: • Select the window SERVICE. • Press Enter • Note the Cal offset value. Update the revolution counters for axes 2 and 3. 5.Calibration Repairs Note! If the final installation makes it impossible to reach the calibration 0 position. Change to the new calibration offset for the axis in question. as follows: • Select the window SYSTEM PARAMETERS. • Topics: Manipulator. check the calibration marks for each axes. • Select axis • Then confirm by pressing OK twice.com EMail:cadserv21@hotmail. • Select axes. • Types: Arm. please inform us.com The document is for study only. Product Manual IRB 2400 www.we will delete 61 .Repairs Calibration 11.6 Calibration equipment For calibration: Axis 1 Axis 2 Axis 3-6 Reference Level indicator Marking equipment: Axis 1-4 Axis 6 3HAB 8223-1 3HAB 8184-1 3HAB 8064-1 6808 0011-LP 6808 0011-GU 3HAB 7981-1 (only 2400/10 and /16) 2111 2021-399 6808 0011-GM 6807 081-D 11. Before start-up.cadfamily.if tort to your rights. make sure that the robot cannot collide with other objects in the working space.7 Operating the robot How to start and operate the robot is described in the User’s Guide.com EMail:cadserv21@hotmail. please inform us.com The document is for study only.cadfamily.we will delete .if tort to your rights.com EMail:[email protected] Repairs 62 Product Manual IRB 2400 www. .........................................6 Teach pendant...............4 I/O units.........................................................................................................................................................8 Miscellaneous........ 11 2......... 11 2..................................................................... 9 2 Control system ............................................. 12 2....................................................................com EMail:cadserv21@hotmail....................................................... axes 5-6 (IRB 2400L) ....................................................2 Operators panel ................3 Upper arm parts.............Spare Parts CONTENTS Page 1 Manipulator .......................................... 2 1................... 5 1......................if tort to your rights..................5 Drive system ..................... 12 www...................1 Mains power................................................................. 10 2.................................................. 10 2.................................................................................................................3 Computer unit ................... axes 4-6 (IRB 2400/10/16).2 Upper arm parts..............4 Drive unit..............we will delete 1 ..............................................cadfamily.....please inform us... 12 2........................7 Contactor unit....................................1 Manipulator...........com Product Manual IRB 2400 The document is for study only.................... 12 2..................................................... axes 4-6 (IRB 2400L) ............................................... 7 1.......................... 2 1........................... TPU 2 ............................... 10 2. cadfamily.www.we will delete .com EMail:[email protected] inform us.com The document is for study only.if tort to your rights. Spare Parts Spare Parts 1 Manipulator Item number refers to item number on the foldouts. 1.1 Manipulator Itm Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 26 33 34 35 1 1 12 12 2 3 12 4 8 1 1 8 12 1 1 1 4 8 1 2 1 2 2 1 1 1 Name Foot Gear box axes 1-3 Hex socket head cap screw Plain washer Motor axes 1 and 3 O-ring Spring washer Hex socket head cap screw Hex socket head cap screw Lower arm Lower arm Spring washer Hex socket head cap screw Spring tension plate Damper, standard axis 2 Damper axis 3 Torx pan head roll. screw Hex socket head cap screw Parallel arm Sealing ring Groove ball bearing Sealing ring Hex socket head cap screw Locking washer Hex socket counters, head Back-up ring Art. no 3HAC 5945-1 3HAC 4795-1 3HAB 3402-69 9ADA 312-9 3HAC 4789-1 2152 2012-434 2154 2033-9 3HAB 3402-45 3HAB 3402-37 3HAC 4796-1 3HAC 4797-1 2154 2033-10 3HAB 3409-50 3HAC 2205-1 3HAC 2180-1 3HAB 5512-1 9ADA 629-56 3HAB 3409-57 3HAB 9394-1 3HAB 3732-13 3HAB 3643-12 3HAB 5515-1 9ADA 183-34 3HAB 5523-1 2121 2852-449 3HAB 5510-1 Rem M12x50 8.8 Gleitmo 610 13x24x2.5 109.5x3 8.4x18x2 M8x65 12.9 Gleitmo 610 M8x25 12.9 Gleitmo 610 2400/10, /16 2400L 10.5x23x2.5 M10x40 12.9 Gleitmo 610 66x116x3 M6x16 M10x60 12.9 Gleitmo 610 V-110-L 99x10.5 61822-2RS1 Acetal (POM) M8x12 SS 1914-04 M8x16 8.8 Acetal (POM) 2 www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Spare Parts 36 41 42 43 46 48 49 50 51 54 55 56 1 Motor axis 2 Lubricating oil Lubricating grease Locking liquid Stop axis 1 Washer Friction washer Sync. mark. axis 2 Upper arm axis 4-6 Lock nut Shaft end Hex socket head cap screw 3HAC 4790-1 1171 2016-604 3HAB 3537-1 1269 0014-429 3HAB 6687-1 2151 2082-150 3HAC 0447-1 3HAB 5522-1 2126 2851-107 3HAB 5527-1 3HAB 7700-71 14 700 ml 1g 1 ml Loctite 243 6.1x20x2 1 2 1 1 1 2 2 2 57 60 62 100 102 102 103 104 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 121 122 2 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 3 1 1 2 1 14 11 1 4 VK-cover Sync. market axis 3 Washer Cable unit axes 1-3 Bottom plate Bottom plate Gasket Cover Cover Gasket Gasket Sealing Bracket Holder for cable guide Cable guide Spring Cable guide upper arm Cover Gasket Instruction plate Serial meas. board Torx pan head roll. screw Battery unit Hexagon nut with flange Cable straps, outdoor Push button unit Distance bolt 3HAA 2166-15 3HAB 8385-1 3HAA 1001-134 3HAC 4791-1 3HAC 7302-1 3HAC 2828-1 3HAC 4554-1 3HAC 3055-1 3HAC 2815-1 3HAC 3200-1 3HAB 5537-1 3HAC 4113-1 3HAB 5923-1 3HAB 3299-1 3HAB 5924-1 3HAB 3662-1 3HAB 5928-1 3HAC 4337-1 3HAC 2589-1 3HAC 2589-1 3HAB 3700-1 9ADA 629-45 4944 026-4 9ADA 290-1 2166 2055-3 3HAC 0017-1 2125 2052-198 See 1.2 and 1.3 M35x1.5 SS 1672-08 M12x60 12.9 Unbrako Gleitmo 610 VK 62x8 Foundry Ext. connections Int. connections Ext. connections Int. connections IRB 2400/10/16 M5x16 M5 fzb L=208 mm M5x15 www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete 3 www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Spare Parts 123 124 125 126 127 128 129 132 132 133 134 135 136 137 138 139 140 141 142 143 145 146 147 149 150 151 152 157 158 165 168 169 170 171 1 1 1 1 1 1 1 1 1 2 1 1 15 3 8 72 6 1 2 1 1 1 1 3 1 Push button cover Push button cover Gasket Cable straps, outdoors Cover customer Gasket Cover Signal cable SMB Signal cable SMB Dust cap Dust cap Dust cap Torx pan head screw Hex socket head pan screw Torx pan head roll. screw Torx pan head roll. screw Cable straps, outdoors Coupling Locking liquid Protective hood Earth symbol Label Hexagon nut Plain washer Gasket Gasket Flange sealing Adhesive tape Bracket Adaptor, customer cabling Adaptor, power cabling Designation sign Protective hood Gasket Cover Cover Profile 3HAC 2744-1 2152 0197-1 3HAB 7267-1 2166 2055-7 3HAB 7266-1 3HAB 7195-1 3HAB 7180-1 3HAC 4050-1 3HAB 3774-1 5217 649-9 5217 649-9 3HAA 1001-630 9ADA 618-56 9ADA 183-34 9ADA 629-34 9ADA 629-44 2166 2055-1 3HAB 3333-20 1269 0014-412 2522 2101-8 3HAB 5617-1 3HAA 1001-513 9ADA 267-6 9ADA 312-6 3HAC 4419-1 3HAB 7160-1 1234 0011-116 1169 9198-301 3HAB 5921-1 3HAB 7328-1 3HAB 7406-1 3HAB 8431-1 3HAC 3189-1 3HAB 9040-1 3HAC 3197-1 3HAC 0048-1 1866 1903-1 Ext. connections Int. connections Int. connections 8.9x780 Int. connections Int. connections Int. connections Ext. connections Int. connections Ext. connections Int. connections M6x16 8.8 M8x12 8.8 M4x12 Ext. conn. M5x12 L=101 mm Loctite 542 D=11.4 - 13 Resolver offset M6 Int. conn. 6.4x12x1.6 Loctite 574 19x0.18 Ext. connections Ext. connections Suspended Ext. connections Ext. connections Int. connections 120 mm 1 1 1 1 1 2 1 1 www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete 4 www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Spare Parts 1.2 Upper arm parts, axes 4-6 (IRB 2400/10/16) Itm Qty 1 1 13 18 18 19 20 21 25 26 27 28 29 30 32 33 34 35 39 40 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 1 1 4 1 1 1 6 15 1 1 2 3 12 12 1 4 Name Upper arm without wrist and motors Upper arm without wrist and motors Disc spring Wrist Wrist O-ring Hex socket head cap screw Plain washer Motor unit axis 5 Motor unit axis 5 Motor unit axes 4 and 6 O-ring Plain washer Hex socket head cap screw Damper axis 4 Hex socket head cap screw Lubricating oil Magnetic plug Sealing ring Bearing grease Flange sealing Sealing ring without dust lip Taper roller bearing Parallel bar, complete Sealing ring without dust lip Damper axis 3 Bracket Backup ring Hex socket counters, head Locking washer Locking liquid Gasket Cable unit axes 4-6 Torx pan head screw Cable straps, outdoors Adhesive tape Cover Art. no Rem 3HAC 1580-1 3HAC 1581-1 3HAB 3731-14 3HAB 9439-1 3HAB 9398-1 3HAB 3772-12 3HAB 3402-38 9ADA 312-7 3HAB 9440-1 3HAB 9442-1 3HAB 9443-1 2152 2011-411 9ADA 312-6 3HAB 3409-26 3HAB 5544-1 3HAB 3402-36 3HAC 0860-1 2522 122-1 2152 2031-6 3HAB 3537-1 1234 0011-116 3HAB 3702-22 3HAA 2103-15 3HAC 1564-1 3HAB 3702-25 3HAB 5511-1 3HAC 0001-1 3HAB 5510-1 2121 2852-449 3HAB 5523-1 1269 0014-429 3HAB 6159-1 3HAC 4793-1 9ADA 618-46 2166 2055-1 1169 9198-301 3HAB 6491-1 Standard Foundry 67.5x50.5x0.7 Std. Foundry Nitrile rubber 126x4 M8x30 8.8 Gleitmo 610 8.4x16x1.6 10 kg 16 kg Nitrile rubber 36.2x3 6.4x12x1.6 M6x25 12.9 Gleitmo 610 M8x20 8.8 Gleitmo 610 2300 ml R1/4” 50 g 30 ml, Loctite 574 32007 X Incl. bearing Nitrile rubber 2 2 2 2 1 2 1 1 1 1 1 3 1 9 9 1 M8x16 8.8 SS 1914-04 6 ml, Loctite 243 M5x20 8.8 2.5x101 500 mm, 19x0.18 www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete 5 www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Spare Parts 57 58 59 1 10 2 1 Cover with lamp unit Torx pan head roll. screw Hex socket head cap screw Customer cable extension, axis 4 3HAC 2774-1 9ADA 629-44 9ADA 183-22 3HAB 6930-1 M5x12 M6x10 Option 043 See below. www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete 6 www.cadfamily.com EMail:[email protected] The document is for study only,if tort to your rights,please inform us,we will delete Spare Parts 1.3 Upper arm parts, axes 4-6 (IRB 2400L) Itm Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 24 25 28 30 31 32 34 35 36 36 37 1 1 1 2 2 1 2 4 1 1 1 6 10 4 1 1 4 1 1 2 2 1 Name Tubular shaft Back-up ring Sealing ring Ball bearing Cover plug Housing, axis 4 Spacer Spacer Spacer Gear, axis 4, step 2 Damper, axis 4 Hex socket head cap screw Plain washer Hex socket head cap screw Drive unit axis 5-6 Motor unit, axis 4 Hex socket head cap screw O-ring Gear unit, axis 4 Plain washer Hex socket head cap screw Cover Lubricating oil Locking liquid Locking liquid Flange sealing Bearing grease Wrist, 5 kg Wrist, 5 kg Hex socket head cap screw Art. no 3HAC 0235-1 3HAB 6354-1 3HAB 3732-13 2213 253-12 2216 264-14 3HAC 0236-1 2159 167-61 2159 167-62 2159 167-63 3HAB 3210-1 3HAB 6356-1 3HAB 3402-24 9ADA 312-6 3HAB 3402-30 Rem 99x10.5 V-110-L 105x130x13 61821-2RSI IRB 2000 D=115/105, T=0.05 D=115/105, T=0.1 D=115/105, T=0.5 M6x16 8.8 Gleitmo 610 6.4x12x1.6 A2F M6x45 8.8 Gleitmo 610 See 1.4 M5x16 8.8 A2F 44.2x3 Nitrile rubber 8.4x16x1.6 A2F M8x30 8.8 A2F 30 ml Loctite 243 Loctite 638 Loctite 574 Shell Retinax MS Std. Foundry M6x20 8.8 Gleitmo 610 3HAC 0238-1 9ADA 183-14 2152 2011-414 3HAB 3380-1 9ADA 312-7 9ADA 183-38 3HAB 6355-1 1171 2016-604 1269 0014-429 1269 0014-413 1234 0011-116 3HAB 3537-1 3HAC 0242-1 3HAC 0243-1 3HAB 3402-25 1 1 6 www.cadfamily.com EMail:[email protected] Product Manual IRB 2400 The document is for study only,if tort to your rights,please inform us,we will delete 7 www.if tort to your rights.we will delete .com The document is for study only.cadfamily.please inform us.com EMail:cadserv21@hotmail. cadfamily.Spare Parts 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 54 55 56 57 58 59 60 61 1 1 39 1 1 1 2 2 6 1 1 1 2 1 1 2 2 1 1 1 1 1 3 1 Cover Cover with lamp unit Torx pan head roll screw Cover Gasket Gasket Sealing ring (without dust lip) Taper roller bearing Cable straps. complete Damper.com Product Manual IRB 2400 The document is for study only. outdoors 3HAB 7384-1 3HAC 2743-1 9ADA 629-44 3HAB 7385-1 3HAB 7388-1 3HAB 7387-1 3HAB 3702-22 3HAA 2103-15 2166 2055-1 2166 2018-8 2166 2018-2 3HAB 3230-1 9ADA 629-47 3HAC 1563-1 3HAB 5511-1 9ADA 183-22 3HAB 3702-25 3HAB 5510-1 3HAA 2356-11 3HAB 3402-36 3HAB 5927-1 3HAC 4794-1 3HAB 6159-1 2166 2055-3 M5x12 8 D=42/55 W=8 Nitrile rubber D=35/62 W=18 32007 X 2.5x101 Polyamide 6.8 A2F D=40/62 W=7 Nitrile rubber 30.please inform us. axis 3 Hex socket head cap screw Sealing ring (without dust lip) Backup ring Locking washer Hex socket head cap screw Cable bracket upper arm Cable unit axes 4-6 Gasket Cable straps.we will delete 8 .6 black D=6 5562-00-04 D=11 5562-00-07 M5x25 8 A2F Incl.if tort to your rights.com EMail:cadserv21@hotmail. outdoors Clamp Clamp Bracket. bearing M6x10 8.1x6 Acetal (POM) black 9x35x3 M8x20 8. axes 5-6 Torx pan head roll screw Parallel bar.8 Gleitmo 610 www. if tort to your rights.com EMail:[email protected] inform us.cadfamily.com The document is for study only.we will delete .www. axes 5-6 Motor unit axes 5-6 Motor plate Hexagon nut Hex socket head cap screw Plain washer Gear belt Art.8 Gleitmo 610 5. no 3HAC 5552-1 3HAC 0241-1 3HAA 2504-1 9ADA 267-5 3HAB 3402-14 9ADA 312-5 3HAA 2393-1 Rem M5 8 A2F M5x16 8.3x10x1 A2F www. axes 5-6 (IRB 2400L) Itm Qty 1 2 3 4 5 6 7 1 2 1 8 10 10 2 Name Drive shaft unit.com Product Manual IRB 2400 The document is for study only.if tort to your rights.Spare Parts 1.com EMail:[email protected] inform us.we will delete 9 .4 Drive unit.cadfamily. please inform us.com The document is for study only.if tort to your rights.com EMail:[email protected] will delete .www.cadfamily. 3 A Fuse 3. F2 T1. 5x20 mm T1 T1. external axes T2. 191 S1.2 S1.15 A Art. 193 opt. FU1 T1. 149.if tort to your rights. 2.1 Name Cam switch key Cam switch (operat.com Product Manual IRB 2400 The document is for study only. FU2 2.please inform us.we will delete opt. When more than one article number exists for an item. no. 3HAB 8868-1 3HAC 2349-1 3HAC 3116-1 3HAB 7818-1 SK 616 003-A SK 616 001-A 5911 069-10 3HAB 5171-1 3HAB 8230-1 3HAC 0420-7 24 VDC Rem opt. the Configuration list informs of the current equipment.1 Mains power Itm Qty Z1 Q1 F1 T1 Name Mains filter Mains filter Rotary switch Door interlock Circuit breaker Circuit breaker Transformer unit 200-400 V Transformer unit 400-500 V Transformer unit 475-600 V Transformer unit 200-400 V Transformer unit 400-500 V Transformer unit 475-600 V Automatic fuse drive system Automatic fuse power supply Fuse 6. 3HAB 9628-1 3HAC 1475-1 3HAB 5142-1 3HAB 9677-1 3HAB 2017-4 3HAB 2017-7 3HAC 0747-1 3HAC 0749-1 3HAC 0750-1 3HAC 0751-1 3HAC 0752-1 3HAC 0753-1 3HAC 0870-1 3HAC 0871-1 5672 817-22 5672 817-19 Rem 16 A 25 A Option 141 Part of opt. mode selector) Motor ON button Lamp block Contact block Glow lamp Emergency stop button Emergency stop block Duty time counter Art. 142 opt. external axes T2. mode selector) Cam switch (operat. Therefor they must not be replaced by any similar part.Spare Parts 2 Control system Item number refers to detailed circuit diagram. see chapter Circuit Diagram. 5x20 mm slow. 472 10 .2 Operators panel Itm Qty S1. external axes 20 A 10 A slow. no. F1 T1.com EMail:cadserv21@hotmail. Article number (marked with bold text) are specially designed to comply with the requirements on personal safety.cadfamily. 16 A opt.3 P1 D1 Disk drive 3HAB 2480-1 Disk drive ribbon cable 3HAB 7420-1 Disk supply cable 3HAB 7421-1 Cover with cooler 3HAB 7239-1 www. 25 A T1 T1 T1 T2. 147. com EMail:[email protected] inform us.cadfamily.www.if tort to your rights.com The document is for study only.we will delete . no.3 Computer unit Itm Qty G1 Name Power supply Type no. no. 3HAB 5845-1 3HAC 3462-1 3HAC 1620-1 3HAB 2038-1 3HAC 1462-1 3HAC 3130-1 3HAB 5956-1 3HAB 5957-1 3HAC 0373-1 3HNE 00001-1 opt. 292 3HAB 6372-1 3HAC 2424-1 3HAB 2997-1 Rem G2-3 A31 A41 A51 A71 A82 Battery Robot computer Memory board 8 Mb Memory board 16 Mb Main computer 25 MHz Ethernet Board Back plane Wrist band 2.if tort to your rights.com EMail:cadserv21@hotmail. 3HAB 7215-1 3HAB 7229-1 3HAB 7230-1 3HNE 00554-1 3HAB 9669-1 3HAB 7231-1 3HNE 00025-1 3HNE 00006-1 3HNE 00009-1 3HNE 00065-1 3HAB 7216-1 3HAC 0200-1 3HAB 7636-1 3HAB 7418-1 5617 817-17 Slow.com Product Manual IRB 2400 The document is for study only.4 I/O units Itm Qty A81 I/O 1-4 Name Panel unit Digital I/O unit Combi I/O unit Analog I/O unit Relay I/O unit 120 VAC I/O unit Remote I/O unit Interbus-S slave Profibus DP slave Encoder interface unit Mounting kit I/O 1-2 CAN cable I/O 1-2 Mounting kit I/O 1-4 CAN cable I/O 1-4 I/O supply fuse 2 A Type no. DSQC334 DSQC374 DSQC365 DSQC363 DSQC373 DSQC323 DSQC324 DSQC361 DSQC336 DSQC330 DSQC 369 Art.Spare Parts 2.cadfamily. DSQC331 DSQC328 DSQC327 DSQC 332 DSQC 332 DSQC 320 DSQC350 DSQC 351 DSQC 352 DSQC 354 Art.we will delete 11 . 5x20 mm Rem I/O 1-2 I/O 1-4 XT31 www.please inform us. we will delete .www.if tort to your rights.cadfamily.please inform us.com EMail:[email protected] The document is for study only. axes 4-6 3HAB 7311-1 3HAB 9270-1 3HAB 9165-1 3HAB 8028-1 47 Ohm.com EMail:cadserv21@hotmail. Rem 3HNE 00313-1 With backlight 3HNE 00314-1 Standard. 3HAC 2493-1 3HAC 2492-1 3HAC 2534-1 3HAC 2529-1 Rem Option 651 Option 651 Option 652 Option 652 12 www. measurement 7 m Cable.com Product Manual IRB 2400 The document is for study only.we will delete . without backlight 3HNE 00133-1 10 m 2.please inform us. if external axis 7 3HAB 8101-11 3HAB 8101-7 3HAB 8101-6 2400L.6 Teach pendant.7 Contactor unit Itm K1. no.8 Miscellaneous Itm Qty Name Cable. Rem 3HAB 8101-2 3HAB 8101-3 if external axis 3HAB 8101-10 opt. no.if tort to your rights. motor 15 m Art.5 Drive system Itm Qty A0 Name DC link DC1 DC link DC2 DC link DC2T Drive unit ECB Drive unit CCB Drive unit BAD Drive unit fan Complete fan unit R1. TPU 2 Itm Qty Name Complete unit Complete unit Extension cable Art. 200 W A1 A2 E1-2 2.1-2 2 Brake resistor Air filter (in front door) Type no. 391.Spare Parts 2. DSQC345B DSQC 345C DSQC 358C DSQC346E DSQC 346C DSQC 346B Art. K2 K3 R2-3 Qty 2 1 2 Name Motor On contactor Brake contactor DC-link inrush current limiter Art. 3HAB 8757-1 3HAB 8757-1 3HAC 0977-1 10 Ohm. no. motor 7 m Cable. measurement 15 m Cable. no. 50 W Rem 2.cadfamily. cadfamily.com EMail:[email protected] The document is for study only.if tort to your rights.please inform us.we will delete .www. motor 30 m XP5. power-signal 7 m Customer cable. measurement 30 m Cable. XP6 XP5. switch 30 m 3HAC 2540-1 3HAC 2539-1 3HAC 2566-1 3HAC 2566-1 3HAC 2121-1 3HAB 7643-1 3HAC 2125-1 3HAC 2126-1 3HAC 3363-1 3HAC 3364-1 3HAC 3365-1 3HAC 3366-1 Option 653 Option 653 Option 654 Option 654 Option 671 Option 672 Option 673 Option 674 Option 71 Option 72 Option 73 Option 74 www. switch 7 m Cable pos. switch 22 m Cable pos. power-signal 30 m Cable pos.com Product Manual IRB 2400 The document is for study only.if tort to your rights. measurement 22 m Cable. power-signal 22 m Customer cable.we will delete 13 .please inform us. XP6 XP5. motor 22 m Cable. XP6 XP8 Customer cable. XP6 XP5.com EMail:cadserv21@hotmail. power-signal 15 m Customer cable.Spare Parts Cable.cadfamily. switch 15 m Cable pos. cadfamily.if tort to your rights.please inform us.com EMail:[email protected] will delete .com The document is for study only.www. .......................................................cadfamily............................................................................. 1..........................................................if tort to your rights....................................................................... 3 Parts requiring special treatment when scrapping..........Decommissioning CONTENTS Page 1 General .......................... 1 General warning.........................................please inform us...................... 2............................................. 2 Controller .........................................................................com Product Manual The document is for study only............. 1 Manipulators ..........we will delete 1 ................................................. 2 Scrapping......................com EMail:cadserv21@hotmail............ 2 Oil and grease. 2....... 2....... 1............................... 3 3 4 4 4 4 5 www.............................................. com EMail:[email protected] inform us.we will delete .if tort to your rights.cadfamily.com 2 Product Manual The document is for study only.Decommissioning www. Some of them are listed below to facilitate scrapping. 2400 www. connectors. 1 Manipulators Material Lead Batteries.cadfamily. upper arm.we will delete 3 . i. parallel bar/arm Gears. grease Aluminium Examples of components Counter-weight Serial measurement board Cables. sync.please inform us. 640 All robot types All robot types All robot types IRB 1400.if tort to your rights. motors Brakes.com Product Manual The document is for study only.Decommissioning Decommissioning 1 General The components of the robot are manufactured from many different materials. Gearboxes Covers. base-frame. motors Cables. 4400 IRB 6400. lower arm. NiCad or Lithium Copper Cast iron/nodular iron Steel Samarium-Cobalt Neodymium Plastic/rubber (PVC) Oil. etc. drive belts. so that the components can be disposed of in a way that does not have a detrimental effect on anyone’s health or the environment.com EMail:cadserv21@hotmail. upper arm tubular Part of IRB 6400 All robot types All robot types All robot types All robot types IRB 1400. Brakes.e. etc. 1. 2400. brackets Castings in wrist. motors Base. screws. ditches. Incineration may be carried out under controlled conditions in accordance with local regulations.if tort to your rights. Do not dispose of oil and grease near lakes. • Spillage may penetrate the soil causing ground water contamination. Dispose of via an authorised person/contractor in accordance with local regulations. Dismantling instructions can be found in under Repairs. ponds.com 4 Product Manual The document is for study only. connectors. www. Also note that: • Spills may form a film on water surfaces causing damage to organisms. various sheet metal parts Transformers Circuit boards Cables. 2 Oil and grease Where possible. 2. arrange for the oil and grease to be recycled. Oxygen transfer could also be impaired. down drains.Decommissioning 1. teach pendant. covers (drive units. Batteries 2 Scrapping 2.cadfamily. or on to soil. study the dismantling instructions for the component in question.we will delete . I/O units) etc.com EMail:cadserv21@hotmail. 1 General warning Before removing any parts from the manipulator. 2 Controller Material Copper Tin Alu-Zinc sheeting Iron Polyester Plastic/rubber (PVC) Lithium Examples of components Transformers.please inform us. cables Cables Control cabinets. www. The types of robot on which there are such parts are listed below together with a description of how they should be removed.com Product Manual The document is for study only.com EMail:[email protected] 2.if tort to your rights. 3 Parts requiring special treatment when scrapping Special care is needed when removing certain parts from the robot. Before scrapping (melting down.we will delete 5 . or other form of destruction) the springs must be unloaded in a safe way.cadfamily. IRB 4400 Balancing cylinder The balancing cylinder contains 3 preloaded spiral springs. Spiral spring Free length of spiral spring: L = 470 mm Figure 1 Balancing cylinder IRB 4400. before scrapping the part in question.please inform us. com EMail:cadserv21@hotmail. L = 833 mm Type B. Before scrapping (melting down. There are two types of balancing cylinder with different preloading in the springs: Type A Type B 4700 N 5700 N Spiral spring L = 510 mm (compressed) Free length of spiral spring: Type A.com 6 Product Manual The document is for study only. IRB 6400 and IRB 640. or other form of destruction) the springs must be unloaded in a safe way.cadfamily.we will delete . L = 868 mm Figure 2 Balancing cylinder.please inform us.if tort to your rights. www.Decommissioning IRB 6400 and IRB 640 Balancing cylinder The balancing cylinder contains 1-2 preloaded spiral springs. 4 3 2 1 Figure 3 Balancing cylinder IRB 6400C. proceed as follows: 1. Check that the pressure is gone by pressing the piston rod <4> down by hand. Remove the lock ring <3>. 4. 2. www.please inform us.Decommissioning IRB 6400C Balancing cylinder To empty the nitrogen gas from the cylinder. Empty the gas cylinder through the valve <1>. 3.com EMail:cadserv21@hotmail. Remove the piston rod <4>.com Product Manual The document is for study only.we will delete 7 .cadfamily.if tort to your rights. Knock the guide ring <2> downwards so that the lock ring <3> is uncovered. Decommissioning www.cadfamily.com EMail:[email protected] inform us.com 8 Product Manual The document is for study only.we will delete .if tort to your rights.