s4cplus-irb7600 m2000a electrical maintenance training manual

8/9/2019 S4CPlus-IRB7600 M2000A Electrical Maintenance Training Manual

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Product Specification

3HAC 13491-1/M2000/Rev. 4

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 150/3.5


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The information in this document is subject to change without notice and should not be construed as acommitment by ABB Automation Technology Products AB, Robotics. ABB Automation TechnologyProducts AB, Robotics assumes no responsibility for any errors that may appear in this document.

In no event shall ABB Automation Technology Products AB, Robotics be liable for incidental orconsequential damages arising from use of this document or of the software and hardware describedin this document.

This document and parts thereof must not be reproduced or copied without ABB AutomationTechnology Products AB, Robotics’s written permission, and contents thereof must not be imparted toa third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB Automation Technology Products AB,Robotics at its then current charge.

© Copyright 2001 ABB. All rights reserved.Article number: 3HAC 13491-1

Issue: M2000/Rev. 4

ABB Automation Technology Products ABRobotics

SE-721 68 VästeråsSweden


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Product Specification IRB 7600

2 Product Specification IRB 7600 M2000


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Description

Product Specification IRB 7600 M2000 3

1 Description

1.1 Structure

A new world of possibilities opens up with ABB’s new Power Robot family. It comesin three versions, 500 kg, 400 kg, and 150 kg handling capacities.The IRB 7600 is ideal for heavy-weight applications, regardless of industry. Typicalareas can be handling of heavy fixtures, turning car bodies, lifting engines, handlingheavy parts, loading and unloading of machine cells, alternatively handling large andheavy pallet layers.

There is more to this benchmark product than sheer power. We have added a range ofsoftware products - all falling under the umbrella designation of Active Safety - to

protect not only personnel in the unlikely event of an accident, but also the robot itself.When handling payloads of 500 kg, it is clear that safety features are vital in protectingthe new investment.

There are a large number of process options for spot welding and material handlingintegrated in the robot. For a complete description of process options for spot weldingsee the Product Specification SpotPack.

The robot is equipped with the operating system BaseWare OS. BaseWare OS controlsevery aspect of the robot, like motion control, development and execution ofapplication programs, communication etc. See Product Specification S4Cplus.

For additional functionality, the robot can be equipped with optional software for

application support - for example spot welding, communication features - networkcommunication - and advanced functions such as multi-tasking, sensor control, etc.For a complete description on optional software, see the Product SpecificationRobotWare Options.

Figure 1 The IRB 7600 manipulator has 6 axes.

Axis 1

Axis 6

Axis 5

Axis 4

Axis 3

Axis 2


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Description


Different robot versions

The IRB 7600 is available in three versions. The following different robot types areavailable:

Standard:

IRB 7600 - 500 kg / 2.3 mIRB 7600 - 400 kg / 2.55 mIRB 7600 - 150 kg / 3.5 m

Definition of version designation

IRB 7600 Mounting - Handling capacity / Reach

Manipulator weight IRB 7600-500/2.3 2490 kgIRB 7600-400/2.55 2500 kgIRB 7600-150/3.5 2530 kg

Airborne noise level:The sound pressure level outside ≤ 73 dB (A) Leq (acc. tothe working space Machinery directive 98/37/EEC)

Power consumption at maximum load:ISO Cube 3.4 kWNormal robot movements 5.8 kW

Prefix Description

Mounting - Floor-mounted manipulator

Handling capacity yyy Indicates the maximum handling capacity (kg)

Reach x.x Indicates the maximum reach at wrist centre (m)


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Description


Figure 2 View of the manipulator from the side and rear (dimensions in mm). Allow 200 mm for cables behind the manipulator foot.

1056

806 250

7600-500/2.3

7600-400/2.55

IRB 7600-500/2.3

IRB 7600-400/2.55

806 250

2012 2507600-150/3.50

IRB 7600-150/3.5 2012 250

250


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Description


Figure 3 View of the manipulator from above (dimensions in mm)

R700

R700

Fork li ft device

200

Robot power cable

Hebevorrichtung für GabelstaplerFork lift device


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Description


1.2 Safety/Standards

The robot conforms to the following standards:

EN 292-1 Safety of machinery, terminology

EN 292-2 Safety of machinery, technical specifications

EN 954-1 Safety of machinery, safety related parts of controlsystems

EN 60204 Electrical equipment of industrial machines

IEC 204-1 Electrical equipment of industrial machines

ISO 10218, EN 775 Manipulating industrial robots, safety

ANSI/RIA 15.06/1999 Industrial robots, safety requirements

ISO 9787 Manipulating industrial robots, coordinate systems

and motions

IEC 529 Degrees of protection provided by enclosures

EN 50081-2 EMC, Generic emission

EN 61000-6-2 EMC, Generic immunity

ANSI/UL 1740-1996 (option)Standard for Industrial Robots and RoboticEquipment

CAN/CSA Z 434-94 (option)Industrial Robots and Robot Systems - GeneralSafety Requirements

The robot complies fully with the health and safety standards specified in the EEC’sMachinery Directives.

The Power Robot Generation is designed with a unique combination of robot power andcontrol system intelligence.

The Service Information System (SIS)The service information system gathers information about the robot’s usage and by thatdetermines how hard the robot has been used. The usage is characterised by the speed,the rotation angles and the load of every axis.With this data collection, the service interval of every individual robot of this generationcan be predicted, optimising and planning ahead service activities. The collection data

is available via the teach pendant or the network link to the robot.

The Power Robot Generation is designed with absolute safety in mind. It is dedicated toactively or passively avoid collisions and offers the highest level of safety to theoperators and the machines as well as the surrounding and attached equipment. Thesefeatures are presented in the active and passive safety system.

The Active Safety System

The active safety system includes those software features that maintain the accuracy of

the robot’s path and those that actively avoid collisions which can occur if the robotleaves the programmed path accidentally or if an obstacle is put into the robot’s path.


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Description


The Active Brake System (ABS)All robots run with an active brake system that supports the robots to maintain theprogrammed path even in an emergency situation.The ABS is active during all stop modes, braking the robot to a stop with the power ofthe servo drive system along the programmed path. After a specific time the mechanicalbrakes are activated ensuring a safe stop even in case of a failure of the drive system ora power interruption.The maximal applicable torque on the most loaded axis determines the stoppingdistance.The stopping process is in accordance with a class 1 stop.While programming the robot in manual mode a class 0 stop, with mechanical brakesonly, applies.

The Self Tuning Performance (STP)The Power Robot Generation is designed to run at different load configurations, manyof which occur within the same program and cycle.The robot’s installed electrical power can thus be exploited to lift heavy loads, create a

high axis force or accelerate quickly without changing the configuration of the robot.Consequently the robot can run in a “power mode” or a “speed mode” which can bemeasured in the respective cycle time of one and the same program but with differenttool loads. This feature is based on QuickMoveTM.The respective change in cycle time can be measured by running the robot in NoMotion-Execution with different loads or with simulation tools, like RobotStudio.

The Electronically Stabilised Path (ESP)The load and inertia of the tool have a significant effect on the path performance of arobot. The Power Robot Generation is equipped with a system to electronically stabilisethe robot’s path in order to achieve the best path performance.As the path performance as such is measured in a combination of speed and path accurac,the user can choose himself the optimal configuration by applying the parameter “Worl-dAccLim” which can limit the linear acceleration along a programmed path.This has an influence while accelerating and braking and consequently stabilises thepath during all motion operations with a compromise of the best cycle time. This featureis secured through TrueMoveTM.

Over-speed protectionThe speed of the robot is monitored by two independent computers.

Restricting the working spaceThe movement of each axis can be restricted using software limits.

As options there are safeguarded space stops for connection of limit switches to restrictthe working space.Axes 1-3 can also be restricted by means of mechanical stops.

Collision detection (option)In case an unexpected mechanical disturbance occurs, like a collision, electrode sticking,etc., the robot will detect the collision, stop on the path and slightly back off from its stopposition, releasing tension in the tool.

The Passive Safety System

The Power Robot Generation has a dedicated passive safety system that by hardwareconstruction and dedicated solutions is designed to avoid collisions with surroundingequipment. It integrates the robot system into the surrounding equipment safely.


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Compact robot arm designThe shape of the lower and upper arm system is compact, avoiding interference intothe working envelope of the robot.The lower arm is shaped inward, giving more space under the upper arm to re-orientatelarge parts and leaving more working space while reaching over equipment in front ofthe robot.The rear side of the upper arm is compact, with no components projecting over the edgeof the robot base even when the robot is moved into the home position.

Moveable mechanical limitation of main axes (option)All main axes can be equipped with moveable mechanical stops, limiting the workingrange of every axis individually. The mechanical stops are designed to withstand acollision even under full load.

Zone switches on main axes (option)All main axes can be equipped with zone switches. The double circuitry to the cam

switches is designed to offer personal safety according to the respective standards.

The Internal Safety Concept

The internal safety concept of the Power Robot Generation is based on a two-channelcircuit that is monitored continuously. If any component fails, the electrical powersupplied to the motors shuts off and the brakes engage.

Safety category 3Malfunction of a single component, such as a sticking relay, will be detected at the nextMOTOR 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 modeThe robot can be operated either manually or automatically. In manual mode, the robotcan only be operated via the teach pendant, i.e. not by any external equipment.

Reduced speedIn 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 ofthe robot. It is also possible to monitor the speed of equipment mounted on the robot.

Three position enabling deviceThe enabling device on the teach pendant must be used to move the robot when inmanual mode. The enabling device consists of a switch with three positions, meaningthat all robot movements stop when either the enabling device is pushed fully in, orwhen it is released completely. This makes the robot safer to operate.

Safe manual movementThe robot is moved using a joystick instead of the operator having to look at the teachpendant to find the right key.

Emergency stopThere 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 safetychain circuit.


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Description


Safeguarded space stopThe robot has a number of electrical inputs which can be used to connect external safetyequipment, such as safety gates and light curtains. This allows the robot’s safetyfunctions 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 a normalprogram stop with no deviation from the programmed path. After approx. 1 second thepower supplied to the motors is shut off.

Hold-to-run control“Hold-to-run” means that you must depress the start button in order to move the robot. Whenthe button is released the robot will stop. The hold-to-run function makes program testingsafer.

Fire safetyBoth the manipulator and control system comply with UL’s (Underwriters Laboratory)

tough requirements for fire safety.

Safety lamp (option)As an option, the robot can be equipped with a safety lamp mounted on the manipulator.This is activated when the motors are in the MOTORS ON state.


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Description


1.3 Installation

All versions of IRB 7600 are designed for floor mounting. Depending on the robotversion, an end effector with max. weight of 150 to 500 kg including payload, can bemounted on the mounting flange (axis 6). See Load diagrams for IRB 7600 generationrobots from page 16 to page 21.

Extra loads (valve packages, transformers) can be mounted on the upper arm with amaximum weight of 50 kg. On all versions an extra load of 500 kg can also be mountedon the frame of axis 1. Holes for mounting extra equipment on page 24.

The working range of axes 1-3 can be limited by mechanical stops. Position switchescan be supplied on axes 1-3 for position indication of the manipulator.

External Mains Transformer

The robot system requires a 475 VAC power supply. Therefore an external transformer

will be included when a mains voltage other than 475V is selected.

Operating requirements

Protection standards

Standard and Foundry Manipulator IP67

Cleanroom standards

Cleanroom class 100 for manipulator according to:

DIN EN ISO 14644: Cleanrooms and associated controlled environments• US Federal Standard 209 e - Air-clean-classes

Explosive environmentsThe robot must not be located or operated in an explosive environment.

Ambient temperatureManipulator during operation +5oC (41oF) to +50oC (122oF)For the controller: Standard +45oC (113oF)

Option +52oC (126oF)

Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)for short periods (not exceeding 24 hours) up to +70oC (158oF)

Relative humidityComplete robot during transportation and storage Max. 95% at constant temperatureComplete robot during operation Max. 95% at constant temperature

Mounting the manipulator

Maximum load in relation to the base coordinate system.

Endurance load Max. load atin operation emergency stop

Force xy ±14000 N ±31000 N

Force z 32000 ±10000 N 39000 ±16000 NTorque xy ±42000 Nm ±72000 Nm

Torque z ±11000 Nm ±19500 Nm

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Figure 4 Hole configuration (dimensions in mm).

8 8 ± 0 . 3

Recommended screws for fastening

M24 x 120 8.8 with 4 mm flat washer

Torque value 775 Nm

the manipulator to a base plate:


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Figure 5 Option Base plate (dimensions in mm).

1 A

A

A

B

B

C C

D

1.5

0.1

A

A - A

50 1 0 o

1 5 o

3 7

, 5 o

B - B C - C

D

522

5

Two guiding pins required, dimensions see Figure 6

3 2 5


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Figure 6 Guide sleeves (dimensions in mm).

Protected from corrosion


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Description


1.4 Load diagrams

The load diagrams include a nominal payload inertia, J0 of 35 kgm2, and an extra load

of 50 kg at the upper arm housing, see Figure 7.

At different arm load, payload and moment of inertia, the load diagram will bechanged.

For an accurate load diagram, please use the calculation program, ABBLoad for 7600on:

• inside.abb.com/atrm, click on Products --> Robots --> IRB 7600

or

• http://www.abb.com/roboticspartner, click on Product range --> Robots --> IRB7600.

Figure 7 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).

Centre of gravity 50 kg

400

200

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Description


Load diagram for IRB 7600-500/2.3

Figure 8 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity).

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

1,20

1,30

0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80

500 kg

475 kg450 kg

425 kg400 kg

300 kg

250 kg

200 kg

150 kg

350 kg

Z (m)

L (m)

2 5 0 m m


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Description


Load diagram for IRB 7600-500/2.3 “Vertical Wrist” (±10o)

Figure 9 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity) at “Vertical Wrist” (±10o), J 0 =35 kgm

2.

For wrist down (0o deviation from the vertical line).Max load = 650kg, Zmax = 0,439m and Lmax = 0,096m

0,0

0,2

0,4

0,6

0,8

1,0

1,2

0,0 0,2 0,4 0,6 0,8 1,0 1,2

600 kg

550 kg

450 kg

300 kg

200 kg

2 5 0

m m

Pay

load

10o 10o

Z

L

“Vertical wrist”


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Description




0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

1,20

1,30

0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80

425 kg

400 kg

350 kg

300 kg

250 kg

200 kg

150 kg

Z (m)

L (m)

2 5 0 m m


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Description



Figure 11 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity) at “Vertical Wrist ” (±10o), J 0 =35 kgm

2.

For wrist down (0o deviation from the vertical line).Max load = 540 kg, Zmax = 0,498m and Lmax = 0,103m

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4

200 kg

300 kg

400 kg

450 kg

500 kg

Pay

load

10o 10o

Z

L


2 5 0 m m


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Description




0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

1,10

1,20

1,30

1,40

1,50

1,60

1,70

1,80

1,90

2,00

0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10

150 kg

140 kg

130 kg

120 kg

110 kg

90 kg

100 kg

80 kg

Z (m)

L (m)

2 5 0 m m


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Figure 13 Maximum permitted load mounted on the robot tool flange at different positions(centre of gravity) at “Vertical Wrist ” (±10o), J 0 =35 kgm

2.

For wrist down (0

o

deviation from the vertical line).Max load = 180kg, Zmax = 0,337m and Lmax = 0,126m

0,0

0,2

0,4

0,6

0,8

1,0

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2

Pay

load

10o 10o

Z

L


2 5 0 m m

150 kg

170 kg

130 kg

110 kg

90 kg


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Maximum load and moment of inertia for full and limited axis 5 (centre line down)movement.

Note. Load in kg, Z and L in m and J in kgm2

Full movement of axis 5 (±120o

):

Axis 5Maximum moment of inertia:

Ja5 = Mass • ((Z+0.250)2 +L2) + max J0L ≤ 500 kgm2

Axis 6Maximum moment of inertia:Ja6 = Mass • L2 + J0Z ≤ 315 kgm

2

Figure 14 Own moment of inertia.

Limited axis 5, centre line down:

Axis 5Maximum moment of inertia:

Ja5 = Load • ((Z+0.250)2 +L2) + J0L ≤ 550 kgm2

Axis 6Maximum moment of inertia:Ja6 = Load • L2 + J0Z ≤ 500 kgm

2

Figure 15 Moment of inertia when axis 5 centre line down.

Z

XCentre of gravity

J0L = Maximum own moment of inertiaaround the maximum vector in the X-Y-plane

J0Z = Maximum own moment of inertia around Z

J0Z = Maximum own moment of inertia around Z

Z

X

Centre of gravity

J0L = Maximum own moment of inertiaaround the maximum vector in the X-Y-plane


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Description


Mounting equipment

Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.Definitions of distances and masses are shown in Figure 16 and Figure 17.The robot is supplied with holes for mounting extra equipment (see Figure 18).Maximum permitted arm load depends on centre of gravity of arm load and robotpayload.

Upper arm

Permitted extra load on upper arm housing plus the maximum handlingweight (See Figure 16):M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension.

/

Figure 16 Permitted extra load on upper arm.

Frame (Hip Load)

Permitted extra load on frame is JH = 200 kgm2.

Recommended position (see Figure 17).JH = JH0 + M4 • R

2

where JH0 is the moment of inertia of the equipmentR is the radius (m) from the centre of axis 1M4 is the total mass (kg) of the equipment including

bracket and harness (≤500 kg)

Figure 17 Extra load on the frame of IRB 7600 (dimensions in mm).

Mounting of hip load

The extra load can be mounted on the frame. Holes for mounting see Figure 20.When mounting on the frame all the four holes (2x2, ∅16) on one side must be used.

806 250Masscentre

a

M1

M1

600

View from above

View from the rear

View from above View from the rear

2 0 0

600

5 4 3

4 7 3

1180

800


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Description


Holes for mounting extra equipment

Figure 18 Holes for mounting extra equipment on the upper and the lower arm (dimensions in mm).

150

M12 (4x)

2512,5

7 8 0

1 0 7 5

1 6 5

250

50

100

4 7 7

M12 (4x)

0

7 7 7

806(1056)(2012)


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Description


Figure 19 Holes for mounting of extra load on the upper arm (dimensions in mm).

Figure 20 Holes for mounting of extra load on the frame, and for mounting of fork lift device(dimensions in mm).

240

M16 (4x)

290290 240

6 0

5 0

M16 (4x)


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Figure 21 The mechanical interface; mounting flange (dimensions in mm).

12 H7 Depth 15

12 H7 Depth 15

A

12x1,6

0,04 A

0,2 A B

0,04 A

B

200

15

1 2 x 3

0

1,6

31

0,02 A

A

A

5

(24)

A - A


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Description


1.5 Maintenance and Troubleshooting

The robot requires only a minimum of maintenance during operation. It has beendesigned to make it as easy to service as possible:

- Maintenance-free AC motors are used.

- Liquid grease or oil is used for the gear boxes.

- The cabling is routed for longevity, and in the unlikely event of a failure, itsmodular design makes it easy to change.

The following maintenance is required:

- Changing filter for the transformer/drive unit cooling every year.

- Changing batteries every third year.

The maintenance intervals depend on the use of the robot. For detailed information onmaintenance procedures, see Maintenance section in the Product Manual.


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1.6 Robot Motion

Type of motion Range of movement

Axis 1 Rotation motion +180o

to-180o

Axis 2 Arm motion +85oto-60o Axis 3 Arm motion +60oto-180o

Axis 4 Wrist motion +300oto-300o Axis 5 Bend motion +100oto-100o Axis 6 Turn motion +300oto -300o

Figure 22 The extreme positions of the robot arm specified at the wrist centre(dimensions in mm).

IRB 7600-500/2.3


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Figure 23 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).

IRB 7600-400/2.55

IRB 7600-150/3.5


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Performance according to ISO 9283

At rated maximum load, maximum offset and 1.6 m/s velocity on the inclined ISO testplane, 1 m cube (for IRB 7600-500/2.3 a 0.63 m cube) with all six axes in motion.

IRB 7600 -400/2.55 -500/2.3 -150/3.5Pose accuracy, AP 0.10 mm 0.13 mm 0.10 mmPose repeatability, RP 0.19 mm 0.24 mm 0.19 mmPath repeatability, RT 1.27 mm 0.34 mm 0.40 mmPose stabilization time, Pst 0.38 s 0.29 s 0.75 s

Velocity

Maximum axis speeds.

IRB 7600 -400/2.55 -500/2.3 -150/3.5Axis no.

1 75° /s 75° /s 100° /s2 60° /s 60° /s 60° /s3 60° /s 60° /s 60° /s4 100° /s 100° /s 100° /s5 100° /s 100° /s 100° /s6 160° /s 160° /s 190° /s

1.7 Cooling fan for axis 1-3 motor (options 113-115)

A motor of the robot needs a fan to avoid overheating if the average speed over timeexceeds the value given in Table 1. The maximum allowed average speed is dependingon the load.

The average speed can be calculated with the following formula:

The maximum allowed average speed for axis 1-3 at the maximum ambienttemperature of 50oC according to Table 1.IP 54 for cooling fan.

Table 1

Variant Maximum

average speed

axis 1 (rpm)

Maximum

average speed

axis 2 (rpm)

Maximum

average speed

axis 3 (rpm)

IRB 7600-500/2.3 5.4 - 7.0 1.4 - 1.5 1.2 - 1.6

IRB 7600-400/2.55 5.4 - 7.0 1.4 - 1.5 1.2 - 1.6

IRB 7600-150/3.5 4.1 - 5.3 1.3 - 1.4 2.2 - 2.9

Average speed =Total axis movement, number of degrees, in one cycle

360 x cycle time (minutes) incl. waiting time

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1.8 DressPack for Material Handling

DressPack options

Dress Pack options include options for Upper arm harness, Lower arm harness andFloor harness. These are described separately below but are designed and meant to beseen as a complete package for either Material handling or Spot welding application.

The Upper Arm Harness consists of a process cable package and supports, clamps,brackets, and a retractor arm. The process cable package contains special designedcables and hoses that have been long term tested. The cables and hoses are partlyplaced in a protective hose to extend the lifetime.

The Upper Arm Harness is designed to follow the robot arm movements and minimise

damages to the harness or the manipulator. The interface to the lower arm harness islocated well protected below the motor for axis 3.

The complete harness is tested and proven to be well suited for both spot weldingapplications and other applications with the same type of movements and very highrequirements. The cable and hose package has a 1000-mm free length at axis 6 forconnection to a robot tool. A tension arm unit keeps hose package in the right positionfor the robot arm movement approved for the DressPack. An arm protection willprevent wearing on the protective hose and on the robot itself. Please note that whenthe robot is operating, some multiply axis movement might end up with anoverstraining of the hose package. These movements must be avoided.

For more information see the Installation and Maintenance Manual.

Figure 24 Mechanical equipment upper arm harness.

Note. The upper arm harness specification is based on the selection of lower armharness.

The Lower Arm Harness consists of a process cable package and supports, clampsand brackets. The process cable package, containing special designed cables and hoses,has been long term tested.

Process Cable package

Tension arm unit

Arm protection

Harness support axis 6

Option 2205


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The process cable package is routed along the lower arm to minimize space requiredand to give no limitation in the robot working envelope. The cables and hoses are partlyplaced in a protective hose to extend the lifetime.

The lower arm harness is connected to the upper arm harness at the connection pointunder the axis 3 motor. The interface plate at the manipulator base is the place wherethe floor harness and the process media are connected.

The Floor Harness consists of signal cables for customer signals. The floor harness isconnected to the lower arm harness at the interface plate at the manipulator base and tothe left side of the control cabinet. The signal connection inside the control cabinetdepends on chosen options. As example bus option and parallel option mean differentconnections.

The cables and hose which are used to form the DressPack for the Material Handlingapplication has the following specification and capacity:

* Quad twisted under separate screen. Can also be used for very sensitive signals

Process cable package

For material handling the DressPack can be chosen in different configurations, wheredetails of the signals and media are added.

Option 056 Connection to manipulator

No floor cables for the DressPack are chosen. The connector at the base for interfacingis specified in the installation and maintenance manual. Terminal connections could befound in the circuit diagrams.

Table 2

Type Pcs Area Allowed capacity

Customer Power (CP)

Utility Power

Protective Earth

2+2

1

0,5 mm2

1,0 mm2500 VAC, 5 A rms

500 VAC

Customer Signals (CS)

Signals twisted pair

Signals twisted pair and

separate shielded

19

4

0,23 mm2

0,23 mm250 VAC/DC, 1 A rms

50 VAC/DC, 1 A rms

Customer Bus (CBus)

Bus signals

Bus signals

Bus signals

Bus utility signals

2

2

4

4

0,18 mm2

0,18 mm2

0,18 mm2

0,23 mm2

Profibus 12 Mbit/s spec*

Can/DeviceNet spec*

Interbus spec*

50 VAC/DC, 1 A rms

Media

Air (PROC 1) 1 12,5 mm

inner

diameter

Max. pressure 16 bar / 230

PSI


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Description


Option 057 Connection to cabinet

Floor cables for the DressPack are chosen. The number of cables and cable typedepends on chosen options. The length of the process cable package at the floor isspecified under the options below:

- Option 675-678 for parallel communication

- Option 660-663 for bus communication with CANDeviceNet

- Option 665-668 for bus communication with Profibus

- Option 670-673 for bus communication with Interbus

The connection inside the cabinet depends on communication type.

- If parallel communication is chosen, signals are found at terminals inside thecabinet (XT5.1, XT5.2 and XT6)

- If bus communication is chosen, signals are both routed to valid bus card. Theremaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).

Communication

Option 2063 Parallel communication

The process cable package has been chosen for parallel communication. The numberas well as the type of signals are defined under Material handling application, Option2204, 2205.

Option 2064 Bus communication

The process cable package has been chosen for bus communication. This alternativeincludes both the signals for the bus communication as well as some parallel signals.The number as well as the type of signals are defined under Material handlingapplication, Option 2204, 2205. The type of bus is defined by the choice of floorcabling (see also option 057)

Option 2204 Material Handling axis 1 to axis 3

The Lower arm harness for the Material Handling has been chosen. This includes the

process cable package as well as brackets, connectors etc. to form a complete dressingpackage from manipulator base to connectors on axis 3. Depending on the choiceabove the process cable package will have different content. See tables below.

For all process cable packages some of the content are common. These common partsfor Material Handling application are shown in Table 3 below. Unique parts fordifferent option combinations are shown in Table 4, Table 5 and Table 6. These tablesare valid for option 2204 and 2205.


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Description


Figure 25 Material Handling from base to axis 3, and Material Handling from axis 3 to axis 6.

Table for Common content Material Handling (with option 2063/2064)

Table for Material Handling with option 2063

* Terminals inside the cabinet if option 057 is chosen** At manipulator base or axis 3 interface (or axis 6 under option 2205)

Table 3

Type Pieces at

Connection point

Note Allowed capacity

Media

Air (PROC 1) 1 12,5 m inner

diameter

Max pressure 16 bar / 230 PSI

Table 4

Type Pieces at

Terminal*

Pieces at

Connection point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1

500 VAC, 5 A rms

500 VAC

Customer Signals (CS)Signals twisted pair

Signals twisted pair and

separate shielded

19

4

19

4

50 VAC, 5 A rms

50 VAC, 5 A rms

From base to axis 3 From axis 3 to axis 6

option 2204

option 2205


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Description


Table for Material Handling with option 2064 and Can/DeviceNet


Table for Material Handling with option 2064 and Interbus


Option 2205 Material Handling axis 3 to axis 6

The Upper arm harness for the Material Handling has been chosen. This includes theprocess cable package as well as brackets, connectors etc. to form a complete dressingpackage from interface at axis 3 to the connectors at axis 6. Depending on the earlierchoice (see option 2204) the process cable package will have different content.For content see Table 3, Table 4, Table 5 and Table 6. See also Figure 24.

The connector type at the manipulator base, at axis 3 and axis 6 is specified in theinstallation and maintenance manual.

Table 5

Type Pieces at

Terminal*

Pieces at

Connection point**

Allowed capacity

Customer Power (CP)

Utility Power

Protective earth

2+2

1

2+2

1

500 VAC, 5 A rms

500 VAC

Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

4

2

2

4

4

Can/DeviceNet spec

50 VAC, 1 A rms

50 VAC, 1 A rms

50 VAC, 1 A rms

Table 6

Type Pieces at

Terminal*

Pieces at

Connection point**

Allowed capacity

Customer Power (CP)

Utility PowerProtective earth

2+21

2+21

500 VAC, 5 A rms500 VAC

Customer Bus (CBus)

Bus signals

Bus signals


Utility signals

4

3

4

1

4

3

Interbus spec

50 VAC, 1 A rms

50 VAC, 1 A rms

50 VAC, 1 A rms


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Description



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Specification of Variants and Options


Communication

2063 ParallelIncludes customer power CP, customer signals CS and Air for MH-process cable

package.

2064 BusIncludes CP, Air and CAN/DeviceNet, Interbus or Profibus for MH-process cablepackage.

Figure 26 Location of MH connections on the foot.

Figure 27 Location of MH connections on axis 3.

R1.SW1 R1.MP R1.SMB

R1.SW2/3 R1.PROC1

R1.CP/CS

1 x 1/2”

R3.FB7

R2.CP/CS

R2.PROC1 1 x 1/2” R2.MP 5/6


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Connection to

056 ManipulatorThe signals are connected directly to the manipulator base to one heavy duty industrialhousing with a Harting modular connector R1.CP/CS, see Figure 26.

The cables from the manipulator base are not supplied.

057 CabinetThe signals CP/CS are connected to 12-pole screw terminals, PhoenixMSTB 2.5/12-ST-5.08, in the controller.The cable between R1.CP/CS and the controller is supplied.For information about the limited number of signals available,see DressPack options on page 31.

Connection to cabinet (Cable lengths)

Parallel/CANDeviceNet/Interbus/Profibus

675/660/670/665 7m676/661/671/666 15m678/663/673/668 30m

EQUIPMENT

691 Safety lampA safety lamp with an orange fixed light can be mounted on the manipulator.The lamp is active in MOTORS ON mode.The safety lamp is required on a UL/UR approved robot.

092 Fork lift deviceLifting device on the manipulator for fork-lift handling.Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled inorder to use fork lift device.

087 Base plateSee chapter 1.3 Installation, for dimension drawing.

091 Brake release coverA cover for the break release buttons.

113 Cooling fan for axis 1 motor (IP 54)Cannot be combined with Cooling fan for axis 2 motor option 114.For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).See Figure 28.Not for protection Foundry.

114 Cooling fan for axis 2 motor (IP 54)For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).Not for protection Foundry.

115 Cooling fan for axis 3 motor (IP 54)

For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).See Figure 28.Not for protection Foundry.


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088 Upper arm coversIncluded in protection Foundry.See Figure 29.

Figure 28 Cooling fan for axis 1 motor and axis 3 motor.

Figure 29 Upper arm covers.

CONNECTION KITS

The connectors fit to the connectors at the manipulator base, axis 3 and 6 respectively.The kit consists of connectors, pins and sockets.

2220 R1.CP/CS and PROC1For the Customer Power/Customer Signal connector and one Process connector on themanipulator base. Sockets for bus communication are included.

2221 R1.WELD and PROC2-4For the Weld connector and three Process connectors on the manipulator base.

2222 R1.SW1 and SW2/3For the position switch asis 1 connector and the position axis 2/3 connector on themanipulator base.

Option 115

Option 113

Option 088


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2223 R3.FB7For the 7-axis connector on the manipulator base.

2224 R2.CP/CS and PROC1For the Customer Power/Customer Signal connector and one Process connector ataxis 3. Pins for bus communication are included.

2225 R2.WELD and PROC2-4For the Weld connector and three Process connectors at axis 3.

2070 WELD and PROC1-4 axis 6Weld connector and four Process connectors at axis 6, the manipulator side.

POSITION SWITCHES

Position switches indicating the position of the three main axes. Rails with separateadjustable cams are attached to the manipulator. The cams, which have to be adaptedto the switch function by the user, can be mounted in any position in the working rangefor each switch. No machining operation of the cams is necessary for the adaptation,simple hand tools can be used.

For axis 1, there are three redundant position zones available, each with twoindependent switches and cams. For axes 2 and 3, two redundant position zones areavailable, each with two independent switches and cams.

For axis 1 it is possible to mount a second set of position switches, doubling the numberof redundant zones to six.

Each position zone consists of two switches mechanically operated by separate cams.Each switch has one normally open and one normally closed contact. See ProductSpecification S4Cplus.The design and components fulfil the demands to be used as safety switches.These options may require external safety arrangements, e.g. light curtains, photocellsor contact mats.

The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/ 3, see Figure 26), or to the controller. In the controller the signals are connected toscrew terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and

EN 60947-5-2.

Connection to

075 ManipulatorConnection on the manipulator base with one/two FCI Sealok 32-pin connector.

076 CabinetConnected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in thecontroller. Position switch cables are included.

Position switches axis 1071 Three redundant position zones are available, each with two independent switches and

cams.


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Accessories


3 Accessories

There is a range of tools and equipment available, specially designed for the robot.

Basic software and software options for robot and PC

For more information, see Product Specification S4Cplus, and Product SpecificationRobotWare Options.

Robot Peripherals

- Track Motion

- Tool System

- Motor Units

- Spot welding system for transformer gun

Tools

Brake release box Includes six brake release buttons and 24V battery unit which can be connected toR1.BU on the manipulator frame. The brake release box can be ordered fromABB Automation Technology Products AB, Robotics, department S.

Calibration CubeThis calibration tool can be ordered from ABB Automation Technology Products AB,

Robotics, department S.


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Accessories



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Index


4 Index

A

accessories 43

Active Brake System 8

Active Safety System 7

C

Collision detection 8

colours 37

cooling device 4

E

Electronically Stabilised Path 8

emergency stop 9

enabling device 9

equipment

mounting 23

permitted extra load 23

F

fire safety 10fork lift device 39

H

hold-to-run control 10

hole configuration 12

holes for mounting extra equipment 24

humidity 11

I

installation 11Internal Safety Concept 9

L

lifting device 39

load 11

load diagrams 15

M

maintenance 27

manipulator colour 37mechanical interface 26

motion 28

mounting

extra equipment 23robot 11

mounting flange 26

N

noise level 4

O

operating requirements 11

options 37

overspeed protection 8

P

Passive Safety System 8

payload 11

position switches 41

protection 37

protection standards 11

R

range of movement 28

reduced speed 9

Robot Peripherals 43

robot versions 4

S

safeguarded space stop 10

delayed 10

safety 7

Safety category 3 9

safety lamp 10, 39Self Tuning Performance 8

service 27

Service Information System 7

space requirements 4

standards 7

structure 3

T

temperature 11

troubleshooting 27


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Index


V

variants 37

W

weight 4

working space

restricting 8, 11, 42

Z

zone switches 9


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Product Specification S4Cplus

CONTENTSPage

Product Specification S4Cplus M2000/BaseWare OS 4.0 1

1 Description ....................................................................................................................... 3

1.1 Structure.................................................................................................................. 3

1.2 Safety/Standards..................................................................................................... 5

1.3 Operation ................................................................................................................ 7

Operator’s panel..................................................................................................... 9

1.4 Memory .................................................................................................................. 11

Available memory.................................................................................................. 11

1.5 Installation .............................................................................................................. 12

Operating requirements.......................................................................................... 12

Power supply.......................................................................................................... 12

Configuration ......................................................................................................... 13

1.6 Programming .......................................................................................................... 13

Movements............................................................................................................. 14

Program management ............................................................................................ 14

Editing programs.................................................................................................... 15

Testing programs.................................................................................................... 15

1.7 Automatic Operation .............................................................................................. 15

1.8 The RAPID Language and Environment................................................................ 16

1.9 Exception handling................................................................................................. 17

1.10 Maintenance and Troubleshooting ....................................................................... 17

1.11 Robot Motion........................................................................................................ 18

Motion concepts..................................................................................................... 18

Coordinate systems ................................................................................................ 18

Stationary TCP....................................................................................................... 20

Program execution ................................................................................................. 20

Jogging................................................................................................................... 20

Singularity handling............................................................................................... 20Motion Supervision................................................................................................ 20

External axes .......................................................................................................... 21

Big Inertia .............................................................................................................. 21

Soft Servo............................................................................................................... 21

1.12 External Axes ....................................................................................................... 21

1.13 I/O System............................................................................................................ 23

Types of connection ............................................................................................... 24

ABB I/O units (node types) ................................................................................... 24

Distributed I/O ....................................................................................................... 25

Signal data.............................................................................................................. 26

http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-


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Product Specification S4Cplus

2 Product Specification S4Cplus M2000/BaseWare OS 4.0

System signals........................................................................................................ 27

1.14 Communication .................................................................................................... 29

2 Specification of Variants and Options........................................................................... 31

3 Index................................................................................................................................. 51

http://0.0.0.0/http://0.0.0.0/


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Description


1 Description

1.1 Structure

The controller contains the electronics required to control the manipulator, externalaxes and peripheral equipment.

The controller also contains the system software, i.e. the BaseWare OS (operatingsystem), which includes all basic functions for operation and programming.

Controller weight 250 kg

Controller volume: 950 x 800 x 620 mm

Airborne noise level:The sound pressure level outside < 70 dB (A) Leq (acc. tothe working space Machinery directive 98/37/EEC)

Figure 1 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.

Teach pendant Operator´s panel

Disk driveMains switch


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Description


Figure 2 View of the controller from the front, from above and from the side (dimensions in mm).

200

950980 *

500

500

820

Lifting points * Castor wheels, Option 126

800

250

Extended cover

Option 123

Cabinet extension

Option 124

for forklift

200

Air distance to wall

800

623

71 52


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Description


Safe manual movementThe robot is moved using a joystick instead of the operator having to look at the teachpendant to find the right key.

Over-speed protection

The speed of the robot is monitored by two independent computers.

Emergency stopThere is one emergency stop push button on the controller and another on the teachpendant. Additional emergency stop buttons can be connected to the robot’s safety chaincircuit.

Safeguarded space stopThe controller has a number of electrical inputs which can be used to connect externalsafety equipment, such as safety gates and light curtains. This allows the robot’s safetyfunctions to be activated both by peripheral equipment and by the robot itself.

Delayed safeguarded space stopA delayed stop gives a smooth stop. The robot stops in the same way as at a normalprogram stop with no deviation from the programmed path. After approx. 1 second thepower supplied to the motors shuts off.

Collision detectionIn case an unexpected mechanical disturbance like a collision, electrode sticking, etc.occurs, the robot will stop and slightly back off from its stop position.

Restricting the working spaceThe movement of each axis can be restricted using software limits.There are safeguarded space stops for connection of limit switches to restrict the workingspace.For some robots the axes 1-3 can also be restricted by means of mechanical stops.

Hold-to-run control“Hold-to-run” means that you must depress the start button in order to move the robot. Whenthe button is released the robot will stop. The hold-to-run function makes program testingsafer.

Fire safetyBoth the manipulator and control system comply with UL’s (Underwriters Laboratory)tough requirements for fire safety.

Safety lampAs an option, the robot can be equipped with a safety lamp mounted on the manipulator.This is activated when the controller is in the MOTORS ON state.


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Description


1.3 Operation

All operations and programming can be carried out using the portable teach pendant(see Figure 3) and operator’s panel (see Figure 5).

.

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 andfunction keys. No previous programming or computer experience is required to learnhow to operate the robot. All operations can be carried out from the teach pendant,

which means that an additional keyboard is not required. All information, including thecomplete programming language, is in English or, if preferred, some other majorlanguage. (Available languages, see options on page 35).

DisplayDisplays all information during programming, to change programs, etc.16 text lines with 40 characters per line.

Motion keysSelect the type of movement when jogging.

Navigation keysUsed to move the cursor within a window on the display and enter data.

Menu keysDisplay pull-down menus, see Figure 4.

Function keysSelect the commands used most often.

Window keysDisplay one of the robot’s various windows.These windows control a number of different functions:

- Jog (manual operation)

- Program, edit and test a program

- Manual input/output management

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2

Hold-to-run

Enabling

P4

P5

device

Joystick

Function keys

Motion keysMenu keys

Window

Navigation keys

Display

keys

Cable 10 m

Emergency stopbutton


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Description


- File management

- System configuration

- Service and troubleshooting

- Automatic operation

User-defined keys (P1-P5) Five user-defined keys that can be configured to set or reset an output (e.g. open/closegripper) or to activate a system input.

Hold-to-runA push button which must be pressed when running the program in manual mode withfull speed.

Enabling deviceA push button which, when pressed halfway in, takes the system to MOTORS ON.When the enabling device is released or pushed all the way in, the robot is taken to theMOTORS OFF state.

JoystickThe joystick is used to jog (move) the robot manually; e.g. when programming therobot.

Emergency stop buttonThe robot stops immediately when the button is pressed in.

Figure 4 Window for manual operation of input and output signals.

Using the joystick, the robot can be manually jogged (moved). The user determines thespeed 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 tasks, with dedicated windows for:

- Production

Inputs/Outputs

File

Value

1

0

1

0

1

1

13

Edit View

1 0

4(6)Name

di1

di2

grip1

grip2

clamp3B

feeder

progno

1 Goto ...2 Goto Top

3 Goto Bottom

Menu keys

I/O list

Menu

Line indicator

Cursor

Function keys


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Description


- Programming

- System setup

- Service and installation

Operator’s panel

Figure 5 The operating mode is selected using the operator’s panel on the controller.

Operating mode selector

MOTORS ON

Continuous light

Fast flashing light (4Hz)

Ready for program execution

Note: The motors have been switched on

=

= One of the safeguarded space stops is active

Emergency stopIf pressed in,

MOTORS ON buttonand indicating lamp

Duty time counter

The robot is not calibrated or the revolution counters

Slow flashing light (1 Hz)Note: The motors have been switched off

Indicates the operating time forthe manipulator (released brakes)

Operating mode selector

Automatic mode

Manual mode

at reduced speed

100% Manual modeat full speed

= Running production

Programming and setup

Max. speed 250 mm/s (600 inches/min.)

=

Optional:

Testing at full program speed=

are not updated

pull to release

=

Using a key switch, the robot can be locked in two (or three)different operating modes depending on chosen mode selector:

Equipped with this mode,the robot is not approvedaccording to ANSI/UL


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Description


Both the operator’s panel and the teach pendant can be mounted externally, i.e.separated from 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.


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Description


1.4 Memory

Available memory

The controller has two different memories:

- a fixed DRAM memory of size 32 MB, used as working memory

- a flash disk memory, standard 64 MB, used as mass memory. Optional 128 MB.

The DRAM memory is used for running the system software and the user programs andit is thus divided into three areas:

- system software

- system software execution data

- user RAPID programs, about 5.5 MB, see Figure 6 (when installing differentoptions, the user program memory will decrease, at most by about 0.7 MB).

The flash disk is divided into four main areas:

- a base area of 5 MB, with permanent code for booting

- a release area of 20 MB, where all the code for a specific release is stored

- a system specific data area of 10 MB, where all the run time specific dataincluding the user program for a system is stored at backup

- a user mass memory area which can be used for storing RAPID programs, data,logs etc.

The flash disk is used for backup, i.e. when a power failure occurs or at power off, allthe system specific data including the user program, see Figure 6, will be stored on theflash disk and restored at power on. A backup power system (UPS) ensures the

automatic storage function.

Figure 6 Available memory.

DRAM memory32 MB

Flash disk memory64/128 MB

Boot 5 MB

Release storage20 MB

System data anduser program10 MB

Mass memory areaavailable for

Systemsoft ware

Data

User RAPIDprogram 5.5 MB

the user

Power on -restore

Poweroff -store


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Description


Several different systems, i.e. process applications, may be installed at the same timein the controller, of which one can be active. Each such application will occupy another10 MB of the flash memory for system data. The release storage area will be in commonas long as the process applications are based on the same release. If two differentreleases should be loaded, the release storage area must also be doubled.

For RAPID memory consumption, see RAPID Developer’s Manual. As an example, aMoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in theinstruction (marked with ‘*’) and 168 bytes if a named robtarget is used. In the lattercase, the CONST declaration of the named robtarget consumes an additional 280 bytes.

Additional software options will reduce the available user program memory, most ofthem however only marginally, i.e. the user program area will still be about 5.5 MB.Only the SpotWare option will reduce memory significantly, i.e. down to about 4.8 MBdepending on the number of simultaneous welding guns.

1.5 Installation

The controller is delivered with a standard configuration for the correspondingmanipulator, and can be operated immediately after installation. Its configuration isdisplayed in plain language and can easily be changed using the teach pendant.

Operating requirements

Protection standards IEC529Controller electronics IP54

Explosive environments

The controller must not be located or operated in an explosive environment.

Ambient temperatureController during operation +5oC (41oF) to +45oC (113oF)with option 473 +52oC (125oF)Controller during transportation and storage, -25oC (13oF) to +42oC (107oF)for short periods (not exceeding 24 hours) up to +70oC (158oF)

Relative humidityTransportation, storage and operation Max. 95% at constant temperature

VibrationController during transportation and storage 10-55 Hz: Max. ±0.15 mm55-150 Hz: Max. 20 m/s2

BumpsController during transportation and storage Max. 100 m/s2 (4-7 ms)

Power supply

Mains voltage 200-600 V, 3p (3p + N for certainoptions

Mains voltage tolerance +10%,-15%

Mains frequency 48.5 to 61.8 Hz


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Description


Rated power:IRB 140, 1400, 2400 4.5 kVA (transformer size)IRB 340, 14001, 24001,4400, 6400, 940 7.8 kVA (transformer size)IRB 6600 6 kVAIRB 7600 7.1 kVA

External axes cabinet 7.2 kVA (transformer size)

Computer system backup capacity 20 sec (rechargeable battery)at power interrupt

Configuration

The robot is very flexible and can, by using the teach pendant, easily be configured tosuit the needs of each user:

Authorisation Password protection for configuration and programwindow

Most common I/O User-defined lists of I/O signalsInstruction pick list User-defined set of instructionsInstruction builder User-defined instructionsOperator dialogs Customised operator dialogsLanguage All text on the teach pendant can be displayed in

several languagesDate and time Calendar supportPower on sequence Action taken when the power is switched onEM stop sequence Action taken at an emergency stopMain start sequence Action taken when the program is

starting from the beginning

Program start sequence Action taken at program startProgram stop sequence Action taken at program stopChange program sequence Action taken when a new program is loadedWorking space Working space limitationsExternal axes Number, type, common drive unit, mechanical

unitsBrake delay time Time before brakes are engagedI/O signal Logical names of boards and signals, I/O mapping,

cross connections, polarity, scaling, default value atstart up, interrupts, group I/O

Serial communication Configuration

For a detailed description of the installation procedure, see the Product Manual -Installation and Commissioning.

1.6 Programming

Programming the robot involves choosing instructions and arguments from lists ofappropriate 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 “rememberand type”.

1. Enlarged transformer for external axes


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Description


The programming environment can be easily customized 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 withouthaving to translate (compile) the program.

Movements

A sequence of movements is programmed as a number of partial movements betweenthe positions to which you want the robot to move.

The end position of a movement is selected either by manually jogging the robot to thedesired position with the joystick, or by referring to a previously defined position.

The exact position can be defined (see Figure 7) 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 sizeof the deviation is defined independently for the TCP, the tool orientation andthe external axes.

Figure 7 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 rotation of an external axis)

Program management

For convenience, the programs can be named and stored in different directories.

The mass memory can also be used for program storage. These can then beautomatically downloaded using a program instruction. The complete program or partsof programs can be transferred to/from the network or a diskette.

The program is stored as a normal PC text file, which means that it can be edited using

Stop point Fly-by pointUser-definable distance (in mm)


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Description


Figure 8 The operator dialogs can be easily customised.

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 poweris switched on, at program start and on other occasions. This allows you to customiseeach 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 therobot directly when the power is switched on. For your convenience, the robot savesthe used path, program data and configuration parameters so that the program can beeasily restarted from where you left off. Digital outputs are also set automatically to thevalue prior to the power failure.

1.8 The RAPID Language and Environment

The RAPID language is a well balanced combination of simplicity, flexibility andpowerfulness. It contains the following concepts:

- Hierarchical and modular program structure to support structured programmingand reuse.

- Routines can be Functions or Procedures.

- Local or global data and routines.

- Data typing, including structured and array data types.

- User defined names (shop floor language) on variables, routines and I/O.- Extensive program flow control.

- Arithmetic and logical expressions.

- Interrupt handling.

- Error handling (for exception handling in general, see Exception handling).

- User defined instructions (appear as an inherent part of the system).

- Backward handler (user definition of how a procedure should behave whenstepping backwards).

- Many powerful built-in functions, e.g mathematics and robot specific.

- Unlimited language (no max. number of variables etc., only memory limited).

Windows based man machine interface with built-in RAPID support (e.g. user definedpick lists).

Front A Front B Front C Other Service

Select program to run:


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1.9 Exception handling

Many advanced features are available to make fast error recovery possible.Characteristic is that the error recovery features are easy to adapt to a specificinstallation in order to minimise down time. Examples:

- Error Handlers (automatic recovery often possible without stoppingproduction).

- Restart on Path.

- Power failure restart.

- Service routines.

- Error messages: plain text with remedy suggestions, user defined messages.

- Diagnostic tests.

- Event logging.

1.10 Maintenance and Troubleshooting

The controller requires only a minimum of maintenance during operation. It has beendesigned to make it as easy to service as possible:

- The controller is enclosed, which means that the electronic circuitry isprotected when operating in a normal workshop environment.

- There is a supervision of temperature, fans and battery health.

The robot has several functions to provide efficient diagnostics and error reports:

- It performs a self-test when power on is set.

- Computer status LEDs and console (serial channel) for fault tracing support.

- Errors are indicated by a message displayed in plain language.The message includes the reason for the fault and suggests recovery action.

- Faults and major events are logged and time-stamped. This makes it possible todetect error chains and provides the background for any downtime. The log canbe read on the teach pendant display, stored in a file or printed on a printer.

- There are commands and service programs in RAPID to test units andfunctions.

- LEDs on the panel unit indicate status of the safeguarded switches.

Most errors detected by the user program can also be reported to and handled by thestandard error system. Error messages and recovery procedures are displayed in plainlanguage.

For detailed information on maintenance procedures, see Maintenance section in theProduct Manual.


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1.11 Robot Motion

Motion concepts

QuickMoveTM

The QuickMoveTM concept means that a self-optimizing motion control is used. Therobot automatically optimizes the servo parameters to achieve the best possibleperformance 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 andvelocity.

- 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 possiblecycle time is minimized.

TrueMoveTM

The TrueMoveTM concept means that the programmed path is followed – regardless ofthe speed or operating mode – even after an emergency stop, a safeguarded stop, aprocess stop, a program stop or a power failure.

This very accurate path and speed is based on advanced dynamic modelling.

Coordinate systems

BaseWare includes a very powerful concept of multiple coordinate systems thatfacilitates jogging, program adjustment, copying between robots, off-lineprogramming, sensor based applications, external axes co-ordination etc. Full supportfor TCP (Tool Centre Point) attached to the robot or fixed in the cell (“StationaryTCP”).


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Figure 9 The coordinate systems, used to make jogging and off-line programming easier.

The world coordinate system defines a reference to the floor, which is the startingpoint for the other coordinate systems. Using this coordinate system, it is possible torelate the robot position to a fixed point in the workshop. The world coordinate systemis also very useful when two robots work together or when using a robot carrier.

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 orworkpiece manipulator.

The coordinate systems can be programmed by specifying numeric values or joggingthe 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 andorientation. This means that even if a tool is changed because it is damaged, the oldprogram 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 beredefined.

ObjectZ

Y

X

World coordinates

UserZ

Z

Y

Y

X

X

coordinates

coordinates

X

Y

Z

Base coordinates

Y

Z

X

X

Base coordinates

Tool coordinates

Tool Centre Point (TCP)

Axis 1

Y

Z

XZ

Y

Axis 3

Axis 3

Axis 1

Axis 2

X

Y

Tool coordinates

Tool Centre Point (TCP)


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External axes

Very flexible possibilities to configure external axes. Includes for instance highperformance coordination with robot movement and shared drive unit for several axes.

Big Inertia

One side effect of the dynamic model concept is that the system can handle very bigload inertias by automatically adapting the performance to a suitable level. For big,flexible objects it is possible to optimise the servo tuning to minimise load oscillation.

Soft Servo

Any axis (also external) can be switched to soft servo mode, which means that it willadopt a spring-like behaviour.

1.12 External Axes

The robot can control up to six external axes. These axes are programmed and movedusing 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 for example, a linear robot

carrier and a work piece positioner.

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 investmentcosts, any axes that do not have to be active at the same time, can share the same driveunit.

An external axis is an AC motor (IRB motor type or similar) controlled via a drive unitmounted in the robot cabinet or in a separate enclosure. See Specification of Variantsand Options.

Resolver Connected directly to motor shaftTransmitter type resolver

Voltage ratio 2:1 (rotor: stator)Resolver supply 5.0 V/4 kHz

Absolute position is accomplished by battery-backed resolver revolution counters inthe serial measurement board (SMB). The SMB is located close to the motor(s)according to Figure 10.

For more information on how to install an external axis, see the User’s Guide - ExternalAxes.

External axes for robot types IRB 4400 and IRB 6400X:

When more than one external axis is used, the drive units for external axis 2 andupwards must be located in a separate cabinet as shown in Figure 10.


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External axes for robot types IRB 140, IRB 1400, and IRB 2400:When more than three external axes are used, the drive units for external axis 4 andupwards must be located in a separate cabinet as shown in Figure 10.

External axes for robot types IRB 6600 and IRB 7600:The drive units for all external axes must be located in a separate cabinet as shown inFigure 10.

Figure 10 Outline diagram, external axes.

SMB

Not supplied on delivery

Not supplied on delivery

SMB

MeasurementSystem 1

MeasurementSystem 2

ABB Drives

Drive System 2

Multiple External Axes

Single External Axes

Motor channel

Serial signals formeasurement anddrive system

alt.


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1.13 I/O System

A distributed I/O system is used, based on the fieldbus standard CAN/DeviceNet. Thismakes it possible to mount the I/O units either inside the cabinet or outside the cabinetwith a cable connecting the I/O unit to the cabinet.

Two independent CAN/DeviceNet buses allow various conditions of I/O handling.Both channels can be operating as

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