3hac045800-en

ABB Robotics

Product manualMachine directive safety kit S4C, S4C+, S4C+ Automotive

Trace back information:Workspace Main version a21 (not checked in)Published 2012-12-10 at 08:47:00Skribenta version 1184

Product manual

Machine directive safety kit S4C, S4C+, S4C+ Automotive

Document ID: 3HAC045800-001

Revision: -

Copyright 2012-2012 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English.


ABB ABRobotics Products

SE-721 68 VstersSweden

Table of contents7Overview of this instruction ..............................................................................................................8Safety ................................................................................................................................................

91 About the safety kit

112 Required parts

133 Replacing parts on the teach pendant

174 Replacing parts on the controller

255 Approving and reporting the replacements

27Index

3HAC045800-001 Revision: - 5 Copyright 2012-2012 ABB. All rights reserved.

Table of contents

This page is intentionally left blank

Overview of this instructionPrerequisites

A maintenance/repair/installation craftsman working with an ABB manipulatormust:

be trained by ABB and have the required knowledge of mechanical andelectrical installation/repair/maintenance work.

References

Document IdReference

3HAC045784-001Instruction - Brake testing for manipulators

3HAC027098-001Operating manual - Emergency safety informationSame document num-ber regardless of lan-guage.

3HAC044215-001Operatingmanual - General safety information for S4C and S4Cplusi

i This manual contains all safety instructions from the product manuals for the manipulators and thecontrollers.

Revisions

DescriptionRevision

First edition-


Overview of this instruction

SafetyVoltage related risks

A danger of high voltage is associated with, for example, the following parts:

Be aware of stored electrical energy (DC link) in the controller.

Units such as I/O modules, can be supplied with power from an externalsource.

The mains supply/mains switch

The power unit

The control power supply (S4C 55 VAC, and S4Cplus 230 VAC)

The rectifier unit (262/430 VAC and 400/800 VDC. Note: Capacitors!)

The drive unit (400/800 VDC)

The service outlets (115/230 VAC)

The power supply unit for additional tools, or special power supply units forthe machining process.

The external voltage connected to the control cabinet remains live even whenthe robot is disconnected from the mains.

Additional connections.

Safety regulationsBefore beginning mechanical and/or electrical installations, make sure you arefamiliar with the safety regulations described in the manual Operatingmanual - General safety information for S4C and S4Cplus.

8 3HAC045800-001 Revision: - Copyright 2012-2012 ABB. All rights reserved.

Safety

1 About the safety kitThe machine directive safety kits

The machine directive safety kits contain necessary spare parts to upgrade theS4C, S4C+, and S4C+Automotive controllers to meet the machine directive. Thismanual describes the kits for all three controllers.

Approval and reportingAll of the replacement procedures that are described in this manual must befollowed by a brake test. After a successful brake test, the replacements must beapproved according to a separate report and then uploaded in WebConfig. SeeApproving and reporting the replacements on page 25.

All of the parts in the kit should be replaced at the same time, by the same person,so that one person can sign the approval.

The brake test is described in a separate document. If the brakes are not workingthen the customer must be informed.

Note

The replacement procedure can only be approved if the brake test is successful.


1 About the safety kit

2 Required partsRequired parts

The spare part kits include all the parts that are necessary to replace to fulfill themachine directive.

There are two kits for each controller model, one with and one without the panelboard. The panel board may need replacing, depending on the revision of theboard.

Note

For S4C: If the revision of the panel board (DSQC 331) is in the range of 1 to 7,then it should be replaced. If the revision is 8 or higher then there is no need tochange the panel board.

For S4C+ and S4C+Automotive: If the revision of the panel board (DSQC 509)is in the range of 1 to 4, then it should be replaced. If the revision is 5 or higherthen there is no need to change the panel board.

Tip

The revision of the panel board is printed on the bar code label on the panelboard. The revision number is written as a slash followed by the revision in twocharacter-format, for example /01 or /06. This number is preceded by the DSQCnumber and the article number.

Kits for S4C

Article numberSafety kit

3HAC044339-001Safety kit with the panel board included

3HAC045620-001Safety kit without the panel board included

Kits for S4C+




Kits for S4C+ Automotive





2 Required parts

3 Replacing parts on the teach pendantReplacing the emergency stop

Use this procedure to replace the emergency stop on the teach pendant.

NoteAction

Turn off the power to the controller. If pos-sible, turn off the power to the entire cellor line.

1

Disconnect the teach pendant and place itwith the back facing up. If possible, use anESD protected area.

2

Loosen the screws holding the bottomcase. Lift off the bottom case. Be carefulso that the screws do not get lost.

WARNING

Do no touch any components inside theteach pendant!

3

Release the contact blocks by pulling thelocking device upwards.

4

xx1200001022

Loosen the nut inside the teach pendantand then remove the old holder with con-tact blocks and the emergency stop button.

5

xx1200001023

Gently place the new emergency stop but-ton in place and put back the nut holdingthe emergency stop button.

6

The terminal numbering is the same, thatis, 11, 12, 21, and 22.

Yellow/white = 11 Yellow/brown = 12 White = 21 Green/brown = 22

Move the wires from the old contact blockto the new button.

7

Tighten the nut holding the emergency stopbutton.

8

Continues on next page3HAC045800-001 Revision: - 13



NoteAction

Continue with replacing the enablingswitch, see Replacing the enabling switchon page 14.

9

Replacing the enabling switchUse this procedure to replace the emergency stop on the teach pendant.

NoteAction

xx1200001024

Disconnect the enabling switch cable fromthe board.

1

Loosen the nut and remove the plasticbracket securing the enabling switch but-tons.

2

Remove the cap and release the nut.3

xx1200001025

Remove the enabling switch and thecables.

4

xx1200001026

Put the new enabling switch harness inplace. Secure the cables with tape.

5

Continues on next page14 3HAC045800-001 Revision: -



Continued

NoteAction

Put the plastic bracket back in place andtighten the nut fully.

6

Put the bottom case back in place. Makesure that no cables stick out or getsqueezed.

7

Tighten the screws fully.8

Continue with replacing the parts on thecontroller, see Replacing parts on the con-troller on page 17.

9



Continued

4 Replacing parts on the controllerReplacing parts inside S4C and S4C+

Use this procedure to replace the parts on the S4C and the S4C+ controllers.

NoteAction


1

Open the top cover of the controller andthe two lids covering the brake and motoron contactors.

2

xx1200001027

Remove the auto/manual switch to enableaccess to the auxiliary contact blocks andthe contactors.Lift the red lever on the auto/manual switchup and then pull the switch into the control-ler. Then take out the auxiliary contactblocks and the contactors from the control-ler, with the cables still connected.

3

xx1200001028

For each brake and motor on contactor:1 Disconnect the cables from the

auxiliary contact blocks on the con-tactor. Press the white securingbutton and pull each auxiliary con-tact block from the holder on thecontactor.

2 Reconnect all the cables to the newauxiliary contact block.

3 Disconnect all the cables from thecontactor.

4 To loosen the contactor from the DINrail insert a screwdriver in the slotand push in designated direction.Pull it loose.

5 Mount the new contactor on the DINrail. Reconnect all the cables to thenew contactor.

6 Mount the new auxiliary contactblock to the holder on the contactor.Fasten the screws fully.

4

xx1200001029




NoteAction

xx1200001030

Remove the contact blocks for the motoron button and the emergency stop button.For S4C also remove the contact blocksfor the main switch.

5

Remove the motor on button and theemergency stop button.

6

For S4C also remove the main switch.

For S4C: Remove the old front panel andput the new front panel in place.

7

xx1200001031

Disconnect the harness connector A81.XP6from the panel board.If the connector S1.1 X1 (part of the har-ness) is connected, then disconnect it too.

8

Remove the old harness.9

Install the new harness.10

xx1200001032

Refit the new motor on button and theemergency stop button, and their newcontact blocks.For S4C also refit the auto/manual switchand its contact blocks.

11




Continued

NoteAction

xx1200001033

Secure the lids.12

If needed, continue with replacing thepanel board, seeReplacing the panel boardon page 23.

13

Otherwise close the controller, reconnectthe power supply cables, and continue withapproving the replacements, seeApprovingand reporting the replacements on page25.

Replacing parts inside S4C+ AutomotiveUse this procedure to replace the parts on the S4C+ Automotive controller.

NoteAction


1

xx1200001034

Open the controller door and unplug all thecables from the base connection unit(DSQC 504). Loosen and remove the screwsecuring the unit and then remove the baseconnection unit.

2




Continued

NoteAction

xx1200001035

Loosen the screw holding the contactorboard and pull the contactor board out ofthe controller.

3




Continued

NoteAction

xx1200001028

For each brake and motor on contactor:1 Disconnect the cables from the

auxiliary contact blocks on the con-tactor. Press the white securingbutton and pull each auxiliary con-tact block from the holder on thecontactor.

2 Reconnect all the cables to the newauxiliary contact block.

3 Disconnect all the cables from thecontactor.

4 To loosen the contactor from the DINrail insert a screwdriver in the slotand push in designated direction.Pull it loose.

5 Mount the new contactor on the DINrail. Reconnect all the cables to thenew contactor.

6 Mount the new auxiliary contactblock to the holder on the contactor.Fasten the screws fully.

4

xx1200001029

xx1200001036




Continued

NoteAction

xx1200001037

Remove the contact blocks for the mainswitch, the motor on button, and the emer-gency stop button.

5

Remove the main switch, the motor onbutton, and the emergency stop button.

6

xx1200001038

Disconnect the harness connector A81.XP6from the panel board.If the connector S1.1 X1 (part of the har-ness) is connected, then disconnect it too.Disconnect the harness cable from thepanel board.

7

xx1200001039

Remove the old harness.8

Install the new harness.9




Continued

NoteAction

xx1200001032

Refit the new motor on button, the emer-gency stop button, and the auto/manualswitch, and their new contact blocks.

10

Connect the connector A81.XP6 to thepanel board. If the connector S1.1 X1 (partof harness) was connected, then connectit too.

11

If needed, continue with replacing thepanel board, seeReplacing the panel boardon page 23.

12

Otherwise close the controller, reconnectthe power supply cables, and continue withapproving the replacements, seeApprovingand reporting the replacements on page25.

Replacing the panel boardUse this procedure to replace the panel board, if needed.

NoteAction

Disconnect all cable connectors from thepanel board. Loosen the securing screw.

1

Remove the old panel board.2

Insert the new panel board into the groovesin the bracket.

3

Tighten the securing screw and reconnectall the cable connectors to the panel board.

4

Connect the power to the controller.5

Approve the replacements, see Approvingand reporting the replacements on page25.

6



Continued

5 Approving and reporting the replacementsApproving the replacements

Use this procedure to approve all replacement procedures in this manual.

NoteAction

Switch to manual mode.1

Verify that the following LEDs on the panelboard are lit.

EN MS NS ES1 ES2 GS1 GS2

2

Press the emergency stop button on theteach pendant.

3

Verify that the LEDs EN1 and EN2 on thepanel board are not lit.Check the teach pendant for the errormessages 20202 Emergency Stop openand 10013 Emergency stop state.

Reset the emergency stop and press themotor on button.

4

Press the emergency stop button on thecontroller.

5

Verify that the LEDs EN1 and EN2 on thepanel board are not lit.Check the teach pendant for the errormessages 20202 Emergency Stop openand 10013 Emergency stop state.

Reset the emergency stop and press themotor on button.

6

Jog the manipulator so that all axes aremoved.

7

Switch to automatic mode.8

Verify that the following LEDs on the panelboard are lit.

EN MS NS ES1 ES2 GS1 GS2 AS1 AS2

9

If the brakes are not working then informthe customer. The replacement procedurecan only be approved if the brake test issuccessful.

Test the brakes. See Instruction - Braketesting for manipulators.

10




NoteAction

If the brake test is successful, fill in the re-port and upload it in WebConfig, see Up-loading the report to WebConfig onpage 26.

11

Uploading the report to WebConfigUse this procedure to upload the report of the approved replacements to WebConfig.

NoteAction

http://roboticsportal.se.abb.comLogin to ABB Robotics Service Portal andgo to WebConfig.

1

In the field Serial/Order/Issue type the ro-bot serial number. Click Search.

2

In the sectionSYSTEMSTRUCTURE, clickon the link for the controller.

3

In section MODULE DOCUMENTS, clickUpload document.

4

Click Browse and select your document,Machine Directive Check List.

5

Click Upload document to upload thedocument to WebConfig.

26 3HAC045800-001 Revision: - Copyright 2012-2012 ABB. All rights reserved.


Continued

IndexAapproving replacements, 25

DDSQC 331, 23DSQC 504, 19DSQC 509, 23

Eemergency stop

replacing on controller, 17, 19replacing on teach pendant, 13

enabling switchreplacing, 14

MMachine Directive Check List, 26

Ppanel board, 23

revision, 11

Ssafety, 8

Tteach pendant

emergency stop, 13enabling switch, 14

testing, 25TPU

emergency stop, 13enabling switch, 14

Uupload documents, 26

WWebConfig, 26


Index

Contact us

ABB ABDiscrete Automation and MotionRoboticsS-721 68 VSTERS, SwedenTelephone +46 (0) 21 344 400

ABB AS, RoboticsDiscrete Automation and MotionBox 265N-4349 BRYNE, NorwayTelephone: +47 51489000

ABB Engineering (Shanghai) Ltd.5 Lane 369, ChuangYe RoadKangQiao Town, PuDong DistrictSHANGHAI 201319, ChinaTelephone: +86 21 6105 6666

www.abb.com/robotics

3HA

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5800

-001

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Cover PageTable of contents1 About the safety kit2 Required parts3 Replacing parts on the teach pendant4 Replacing parts on the controller5 Approving and reporting the replacementsIndex

3hac045800-en

Documents

s4c automotivetrace

power unit

control power supply

safety instructions

safety kit112

s4c automotivedocument

rectifier unit

drive unit