Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
504 868-102
2003-10
Control Cabinet
M2001
The information in this document is subject to change without notice and should be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this document.
In no event shall ABB be liable for damages of any nature from the use of this document.
This document and parts thereof must not be reproduced or copied without ABBs written
permission, and the contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose.
Copies of this document can be ordered from ABB.
ABB Automation Technology Products AB
Artikelnummer: 504 868-102
Datum: 2003-10
ABB Automation Technology Products AB
Arc Welding & Application Equipment
S-695 82 Lax
Sverige
Control Cabinet
LIST OF CONTENTS
Page
1
General .........................................................................................................................
1.1
Types of robot ....................................................................................................
5
5
7
7
8
10
11
12
13
13
19
20
21
23
25
28
31
31
34
39
42
47
49
59
3.14
3.15
3.16
3.17
3.18
62
69
72
79
81
89
89
90
92
93
504 868-102
Control Cabinet
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
95
99
106
111
119
125
133
139
147
153
161
169
169
171
173
175
181
219
223
229
267
271
275
281
281
282
282
282
283
Maintenance................................................................................................................. 285
504 868-102
Control Cabinet
General
1 General
1.1 Types of robot
The top cabinet for equipment from the standard product range is adapted for
connection to the control system S4Cplus.
Please refer to the Product and User Guide for
a description of the control system
The product range has been produced for robot types:
- IRB 140/1400/2400 in AW design.
However, some products can, without further modification, be connected in
combination with other robot types.
504868-02_en.fm
Control Cabinet
General
504868-02_en.fm
Control Cabinet
The top cabinet, which is available in two heights 620 mm/ 820 mm, with
interfaces for:
- positioner
- process equipment
- Operator communications and safety equipment
Programming unit
Cabinet_S4Cplus-8
504868-02_en.fm
Control Cabinet
2.2 Connections
2.2.1 External connections
The figure below shows the external connections on the left of the top cabinet.
Connection
Manipulator
Connection
Safety
equipment
Connection
Conveyor
Connection
Process
equipment
Connection
Operator
panel
Cabinet_S4Cplus-7
Connection
External
welding power
source
Figure 2 Connections
The interface modules in the top cabinet are connected to the control system via
a signal interface that distributes the requisite system signals and feeds.
Connections to the different units are made using jackable terminals to facilitate
service and repair work.
504868-02_en.fm
Control Cabinet
skpinsida.jpg
Customer connections
OpCom interface
Positioner interface
Process interface
504868-02_en.fm
Control Cabinet
504049A01
Terminal A204-X2
Terminal A204-X3
Terminal A204-X4
CAN-bus connection
If the "Extended emergency stop" option is included the following signals are also
available:
Terminal A204-X5
10
504868-02_en.fm
Control Cabinet
504868-02_en.fm
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Control Cabinet
12
Frame section
Lock
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Controller IF
Controller InterFace
M2001 620 mm
11
502 146-001
Skp
Cabinet
620 mm
41
502 282-880
Huvudkabelstam
Cable harness
M2001
42
502 285-880
Kabelstam, Op-panel
43
502 796-880
Canbus
Canbus
44
503 172-880
Byglingsdon
Clamping unit
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Control Cabinet
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Controller IF
Controller InterFace
M2001 820 mm
11
502 145-001
Skp
Cabinet
820 mm
41
502 282-880
Huvudkabelstam
Cable harness
M2001
42
502 285-880
Kabelstam, Op-panel
43
502 796-880
Canbus
Canbus
44
503 172-880
Byglingsdon
Clamping unit
504868-02_en.fm
Control Cabinet
42
504049a01
43
44
41
11
504868-02_en.fm
17
Control Cabinet
18
504868-02_en.fm
Control Cabinet
Manipulator interface
3 Manipulator interface
There is a modular based interface fitted to the left of the cabinets rear panel for
the positioner. This may be equipped differently from case to case, depending on
the type of manipulator.
1
6
PosIF.jpg
Motor contactors with interface relay and auxiliary contact blocks for the
manipulator axis
The interface is fitted with internal wiring for connection to the robot control
system. See Figure 6.
504868-03_en.fm
19
Control Cabinet
Manipulator interface
3.1 Connections
Cables to external equipment are connected to the outputs on the left-hand side of
the top cabinet.
Output 2
20
Positioner
504868-03_en.fm
Control Cabinet
Manipulator interface
Axis computer 2
Each axis computer has two drive systems (DS1 and DS2) and two measurement
systems (MS1 and MS2)
Axis computer 1
Drive system 1 (DS1) Drive unit for the robot
Drive system 2 (DS2) Rectifier or Rectifier + a drive unit for the positioner/
conveyor
Axis computer 2
Drive system 1 (DS1) Drive unit for manipulator and/or conveyor
Drive system 2 (DS2) Rectifier or Rectifier + a drive unit for the positioner.
(Only used when the multi-axes IRBP positioner is included in the system, moved
over from drive system 2 on axis computer 1)
Connector
card 1
Cabinet_S4Cplus_3
Connector
card 2
504868-03_en.fm
21
Control Cabinet
Manipulator interface
In order to control positioner IRBP the control cabinet must be ordered with
ABB Robotics option 397 "Prepared for external axes".
Option 397 contains the following components:
- Transformer T4
- Rectifier DC4 including a U type drive unit
- Axis computer 2
- Connector card 2
22
504868-03_en.fm
Control Cabinet
Manipulator interface
Cabinet_S4Cplus_1
or
DC4
DC4
G/U
U
DC0
IRB1400H/IRB2400 DC1
IRB 4400
DC2
IRB 6400
DC4
Drive equipped
IRB 140/1400
Drive
504868-03_en.fm
23
Control Cabinet
Manipulator interface
Drive unit set-up for robots IRB 140/1400/2400
The following drive unit set-ups are available for robots IRB140/1400/2400 with
manipulator IRBP: See Figure 9.
Position 0
Position 3
Position 2
Position 1
Empty
Robot
Robot
Robot
Robot
Position 0
B
24
Position 3
Robot
Position 2
Robot
Position 1
Robot
504868-03_en.fm
Control Cabinet
Manipulator interface
Spare
Measurement
system 2
Drive system 2
connector card 1
Measurement
system 1
Drive system 1
504868-03_en.fm
25
Control Cabinet
Manipulator interface
3.4.2 Axis computer 2
Measurement system 1 (MS1) Spare
Measurement system 2 (MS2) Serial measurement board for manipulator/conveyor
Drive system 1
Drive system 2
Measurement system 2
connector card 2
Measurement system 1
26
504868-03_en.fm
Control Cabinet
Manipulator interface
3.4.3 Resolver connection
The robots/manipulators axes are equipped with a resolver integrated with
respective motors to give exact positioning. See Figure 14
The resolvers are connected to the measurement channel for respective axis on the
serial measurement boards.
skpinsida.jpg
Serial
measurement
board
AC-motor
Skp_S4Cplus_6
Resolver
504868-03_en.fm
27
Control Cabinet
Manipulator interface
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Axis Computer 2
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Manipulator interface
2
Individual drive unit, i.e. one drive unit per motor (axis).
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When direct connection is used, the connected axis follows the robots status with
activation/deactivation.
The motor connectors included in the axis selector are activated/deactivated by
signals from a digital I/O-card.
504868-03_en.fm
29
Control Cabinet
Manipulator interface
30
504868-03_en.fm
Control Cabinet
Positioner interface
504070a01-2
Signal connection
This equipment is intended for installations with welding tables and therefore
contains no drive or measurement systems to control the motor axes.
Station indication (applies for FlexArc Compact C and S)
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, where applicable, that indicate which station is in
the working mode for the robot.
The switches are cross-connected and actuate individual digital inputs in the
control system. Respective inputs are set high when the station changer unit is at
an end position.
504070-01_en.fm
31
Control Cabinet
Positioner interface
1
4
504744c01-2
32
Signal connection
504070-01_en.fm
Control Cabinet
Positioner interface
504744a01-3
Drive system
For this positioner the drive system consists of:
Rectifier DC 4
504070-01_en.fm
33
Control Cabinet
Positioner interface
Axis selector
The manipulators axle is permanently connected to the drive unit and
consequently follows the operating status of the robot with activation/deactivation.
Connecting the manipulator
The motor and resolver signals are gathered in a common output XS103 on the
control cabinet and the manipulator is connected to this output.
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Compact S/C
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Plt, kompl.
Plate, compl.
15
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Digitalt I/O-kort
Digital I/O-board
16
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Anslutningsdon, CombiCon
Connector, CombiCon
7-pol
17
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Insticksbrygga
Address Key
7-pol
23
489 947-601
Anslutningsdon, CombiCon
Connector, CombiCon
24 V
24
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Anslutningsdon, CombiCon
CombiCon
24 V
41
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Kabelstam S
Cable harness S
FlexArc Comp.
11
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OPTION
OPTION
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M2001
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Kabel
Cable
W217
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Sockel
Housing
64-pol
16
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Ram
Frame
A-F
24
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Kpa
Hood
25
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31
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Seriemtkort, kompl.
Serial measurement
board, compl,
31.1
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Seriemtkort
Serial measurement
board
31.5
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Batterienhet
Battery unit
37
502 511-880
Kabel
Cable
W230
38
500 157-001
Skrmklmma
Screen clamp
6-16 mm
39
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Anslutningsdon,CombiCon
Connector, CombiCon
4-pol
41
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Kabelstam, option
42
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Kabel
Cable
13
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31
37
Positioner interface
504070-01_en.fm
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Control Cabinet
Positioner interface
38
504070-01_en.fm
Control Cabinet
Positioner interface
5
6
7
9
3
504071C01-2
10
Resolver connection
Signal connection
Brake relay
Adapter X4
504071-01_en.fm
39
Control Cabinet
Positioner interface
504071a01-3
Drive system
For this positioner the drive system consists of:
Rectifier DC4
40
504071-01_en.fm
Control Cabinet
Positioner interface
Axis selector
A contactor that connects the drive unit voltage to the motor is used to activate the
manipulators axle.
The contactor is operated using a 24V DC amplifier block, which is controlled by a
digital output from the control system. The control voltage for the contact coil is
230V AC.
Activation signals
Activation/deactivation of the manipulators axle can be performed from the
control program or by using the function button under the Jogging menu on the
programming unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.
Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches actuate individual digital inputs in the control system.
Respective inputs are set "high" when the station changer unit is at an end position.
Connecting the manipulator
The motor and resolver signals are gathered in a common output XS101 on the
control cabinet and the manipulator is connected to this output.
Safety
Due to reasons of safety the station changer cannot be set in the operating mode
MAN FS. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the personal safety equipment.
504071-01_en.fm
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Positioner interface
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IRBP C/C Index
M2001
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Sockel
Housing
64-pol
16
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Ram
Frame
6-mod A-F
18
500 861-881
23
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Seriemtkort, kompl.
Serial measurement
board, compl.
23.1
505 966-001
Seriemtkort
Serial measurement
board
SMB
23.5
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Batterienhet
Battery unit
29
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Skrmklmma
Clamp
31
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stn.vxel
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Kabelstam
Cable harness
IRBP C
42
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Kabel
Cable
W 217
43
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Kabel
Cable
W 230
44
502 517-880
Kabel
Cable
W 231
45
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Digitalt I/O-kort
46
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Connector, CombiCon
7-pol
47
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Insticksbrygga
Address key
7-pol
6-16 mm
504071-01_en.fm
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Modulhllare
Module holder
12p
28
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Modulhllare
Module holder
12p
41
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Kabelstam
Cable harness
43
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Kabel
Cable
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Positioner interface
43
27
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Control Cabinet
Positioner interface
46
504071-01_en.fm
Control Cabinet
Positioner interface
7
8
2
10
11
504072D01-2
5
3
Resolver connections
Signal connection
Motor contactors
Brake relay
Adapter X4
504072-01_en.fm
47
Control Cabinet
Positioner interface
504072a01-3
Drive system
For this positioner the drive system consists of:
Rectifier DC4
48
504072-01_en.fm
Control Cabinet
Positioner interface
Axis selector
A contactor that connects the drive unit voltage to the motor is used to activate
respective manipulators axes. The contactor is operated using a 24V DC amplifier
block, which is controlled by a digital output from the control system. The control
voltage for the contact coil is 230V AC.
Activating/deactivating
Activation/deactivation of the manipulators axle can be performed from the
control program or by using the function button under the Jogging menu on the
programming unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.
Connecting the manipulator
The motor and resolver signals for respective manipulators are gathered in a
common output on the control cabinet and the manipulator is connected to this
output. The manipulator for station 1 is connected to output XS101 and the
manipulator for station 2 is connected to output XS102.
Safety
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The function of the
contactors is supervised by the safety equipment.
Options
IRBP 5000L
As an option there is a possibility to receive the axis selector with the cabling,
dimensioned for the large motor currents that are demanded, in order to run this
type of positioner.
504072-01_en.fm
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Control Cabinet
Positioner interface
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19
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Kabel
Cable
W 232
26
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Trefas kontaktorbygel
29
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Byglingsdon
Jumper
If only 1 positioner
39
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Anslutningsdon, CombiCon
Connector, CombiCon
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IRBP 5000 L
M2001
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Kabel
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Kabel
Cable t
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M2001
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Drivdon
Drive unit
2-axes G/U
13
502 338-880
Kabel
Cable
W215-216
14
502 344-001
15
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Sockel
Housing
64-pol
16
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Ram
Frame
6-mod A-F
24
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Kpa
Hood
25
193 715-151
Delad kpa
Shared hood
39
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Anslutningsdon, CombiCon
Connector, CombiCon
41
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Kabelstam
Cable harness
42
502 508-880
Kabel
Cable
4-pol
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Kontaktor
Contactor
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Frstrkarblock
Amplifier block
13
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Hjlpkontaktblock
15
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16
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Digitalt I/O-kort
17
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Anslutningsdon, CombiCon
Connector, CombiCon
7-pol
18
500 958-001
Insticksbrygga
Address key
7-pol
20
505 966-880
Seriemtkort, kompl.
Serial measurement
board, compl.
SMB
20.1
505 966-001
Seriemtkort
Serial measurement
board
20.5
505 966-003
Batterienhet
Battery unit
26
500 157-001
Skrmklmma
Clamp
27
193 715-707
Modulhllare
Module bracket
28
193 715-708
Modulhllare
Module bracket
31
502 152-880
Plt kompl.
Plate compl.
41
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Kabelstam, 2 akt.enhet
42
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Kabel
Cable
W221-223
44
502 341-881
Kabel
Cable
W217
45
502 511-880
Kabel
Cable
W230
46
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Kabel
Cable
W231
6-16 mm
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27
28
42
11
12
13
15
26
20
16
17
18
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46
45
44
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41
57
Control Cabinet
Positioner interface
58
504072-01_en.fm
Control Cabinet
Manipulator interface
7
8
9
10
11
12
504073C01-2
6
4
Resolver connection
Signal connection
Motor contactors
Brake relay
Connection X4
504073-01_en.fm
59
Control Cabinet
Manipulator interface
504073a01-3
2
1
Drive system
For this positioner the drive system consists of:
Rectifier DC4
60
504073-01_en.fm
Control Cabinet
Manipulator interface
Axis selector
A connector is used to activate one of the positioners work stations, this is
connected to the drive unit voltage to the motor in question.
The contactor is operated using a 24V DC amplifier block, which is controlled by a
digital output from the control system. The control voltage for the contact coil is
230V AC.
As standard only one axis can be active at any one time.
Activating/deactivating
Activating/deactivating of the positioners work stations can be performed from:
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.
Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches set individual digital inputs in the control system.
Respective inputs are set "high" when the station changer unit is at an end position.
Connecting the positioner
Motor and resolver signals for the positioner are separated into two outputs on the
control cabinet, and the positioner is connected to these.
- The motors are connected to the output XS101 and
- the resolvers are connected to the output XS102.
Safety
Due to reasons of safety the station changer cannot be set in the operating mode
MAN FS. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the safety equipment.
504073-01_en.fm
61
Control Cabinet
Manipulator interface
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504 073-880
Lgestllargrnssnitt,
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Positioner InterFace,
IRBP R/K/E/F
504 080-880
13
501 111-011
Drivdon
Drive unit
14
502 344-001
Kabel DS (Drivsystem)
15
193 715-110
Sockel
Housing
64-pol
16
193 715-607
Ram
Frame
6-mod A-F
39
505 370-880
Kontaktormodul, stationsvxel
41
504 162-880
Kabelstam
Cable harness
42
502 338-880
Kabel
Cable
11
62
$QWDO
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M2001
2-axes
W215-216
504073-01_en.fm
Control Cabinet
504073C01-1
15
16
13
14
11
41
42
39
Manipulator interface
504073-01_en.fm
63
Control Cabinet
Manipulator interface
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504 080-880
11
193 751-055
Kontaktor
Contactor
12
193 861-002
Frstrkarblock
Amplifier block
13
193 751-105
Hjlpkontaktblock
15
500 861-881
16
501 112-001
Digitalt I/O-kort
17
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7-pol
18
500 958-001
Insticksbrygga
Address key
7-pol
20
505 966-880
Seriemtkort, kompl.
Serial measurement
board, compl.
SMB
20.1
505 966-001
Seriemtkort
Serial measurement
board
20.5
505 966-003
Batterienhet
Battery unit
26
500 157-001
Skrmklmma
Clamp
27
193 715-707
Modulhllare
Module bracket
28
193 715-708
Modulhllare
Module bracket
31
502 152-880
Plt kompl.
Plate compl.
41
504 150-880
Kabelstam, 2 akt.enhet
42
502 505-880
Kabel
Cable
W221-223
44
502 341-881
Kabel
Cable
W217
45
502 511-880
Kabel
Cable
W230
46
502 517-880
Kabel
Cable
W231
6-16 mm
504073-01_en.fm
Control Cabinet
Manipulator interface
27
28
42
11
12
13
15
26
20
16
17
18
504080D01
46
45
44
504073-01_en.fm
41
65
Control Cabinet
Manipulator interface
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Kontaktor
Contactor
12
193 861-002
Frstrkarblock
Amplifier block
13
193 751-105
Hjlpkontaktblock
27
193 715-707
Modulhllare
Module holder
12p
28
193 715-708
Modulhllare
Module holder
12p
41
505 367-880
Kabelstam
Cable harness
43
502 505-880
Kabel
Cable
W221-223
504073-01_en.fm
Control Cabinet
Manipulator interface
43
27
28
11
12
13
505370A01
41
504073-01_en.fm
67
Control Cabinet
Manipulator interface
68
504073-01_en.fm
Control Cabinet
Positioner interface
8
9
10
11
12
504074B01-2
6
4
Resolver connection
Signal connection
Motor contactors
Brake relay
Connection X4
504074-01_en.fm
69
Control Cabinet
Positioner interface
504073a01-3
2
1
Drive system
For this positioner the drive system consists of:
Rectifier DC4
70
504074-01_en.fm
Control Cabinet
Positioner interface
Axis selector
Contactors are used to activate one of the positioners work stations, these are
connected to the drive unit voltage to the motors in question.
The contactors are operated using a 24V DC amplifier block, which is controlled
by a digital output from the control system. The control voltage for the contact
coils is 230V AC.
As standard only one axis can be active at any one time.
Activating/deactivating
Activating/deactivating of the positioners work stations can be performed from:
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactors for the mechanical unit in question are operated via a digital output
on activation. An acknowledgement signal is obtained and a brake release relay
with a digital output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.
Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches set individual digital inputs in the control system.
Respective inputs are set high when the station changer unit is at an end position.
Connecting the positioner
Motor and resolver signals for the positioner are separated into two outputs on the
control cabinet, and the positioner is connected to these.
- The motors are connected to the output XS101 and
- the resolvers are connected to the output XS102.
Safety
Due to reasons of safety the station changer cannot be set in the operating mode
MAN FS. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the safety equipment.
504074-01_en.fm
71
Control Cabinet
Positioner interface
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504 074-880
Lgestllargrnssnitt,
IRBP B/D
Positioner InterFace,
IRBP B/D
504 080-880
13
501 111-011
Drivdon
Drive unit
14
502 344-001
Kabel DS (Drivsystem)
15
193 715-110
Sockel
Housing
16
193 715-607
Ram
Frame
6-mod A-F
19
502 514-880
Kabel
Cable
W232
26
502 780-002
Trefas kontaktorbygel
39
505 370-880
Kontaktormodul, stationsvxel
40
193 715-709
Modulinsats
Module element
41
504 156-880
Kabelstam, 2 kontaktorer
11
72
$QWDO
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M2001
2-axes
64-pol
12-pol
42
502 338-880
Kabel
Cable
W215-216
43
502 505-881
Kabel
Cable
W224-225
504074-01_en.fm
Control Cabinet
504074-01_en.fm
40
504074B01-1
15
16
13
14
19
11
43
41
42
26
39
Positioner interface
73
Control Cabinet
Positioner interface
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504 080-880
11
193 751-055
Kontaktor
Contactor
12
193 861-002
Frstrkarblock
Amplifier block
13
193 751-105
Hjlpkontaktblock
15
500 861-881
16
501 112-001
Digitalt I/O-kort
17
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7-pol
18
500 958-001
Insticksbrygga
Address key
7-pol
20
505 966-880
Seriemtkort, kompl.
Serial measurement
board, compl.
SMB
20.1
505 966-001
Seriemtkort
Serial measurement
board
20.5
505 966-003
Batterienhet
Battery unit
26
500 157-001
Skrmklmma
Clamp
27
193 715-707
Modulhllare
Module bracket
28
193 715-708
Modulhllare
Module bracket
31
502 152-880
Plt kompl.
Plate compl.
41
504 150-880
Kabelstam, 2 akt.enhet
42
502 505-880
Kabel
Cable
W221-223
44
502 341-881
Kabel
Cable
W217
45
502 511-880
Kabel
Cable
W230
46
502 517-880
Kabel
Cable
W231
6-16 mm
504074-01_en.fm
Control Cabinet
Positioner interface
27
28
42
11
12
13
15
26
20
16
17
18
504080D01
46
45
44
504074-01_en.fm
41
75
Control Cabinet
Positioner interface
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Kontaktor
Contactor
12
193 861-002
Frstrkarblock
Amplifier block
13
193 751-105
Hjlpkontaktblock
27
193 715-707
Modulhllare
Module holder
12p
28
193 715-708
Modulhllare
Module holder
12p
41
505 367-880
Kabelstam
Cable harness
43
502 505-880
Kabel
Cable
W221-223
504074-01_en.fm
Control Cabinet
Positioner interface
43
27
28
11
12
13
505370A01
41
504074-01_en.fm
77
Control Cabinet
Positioner interface
78
504074-01_en.fm
Control Cabinet
Positioner interface
7
8
9
3
10
11
12
504075D01-2
Resolver connections
Signal connection
Motor contactors
Brake relay
Adapter X4
504075-01_en.fm
79
Control Cabinet
Positioner interface
504075a01-3
Drive system
For this positioner the drive system consists of:
Rectifier DC4
80
504075-01_en.fm
Control Cabinet
Positioner interface
Axis selector
Two contactors that connect the drive unit voltage to the motors are used to activate
respective manipulators axes. Each contactor is operated using a 24V DC
amplifier block, which is controlled by a digital output from the control system.
The control voltage for the contact coil is 230V AC.
Activating/deactivating
Activating/deactivating of the positioners respective axes can be performed from
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactors for the axes in question are operated via a digital output on
activation. After the ready signal on the acknowledgement input, the brake release
relay is activated by a digital output.
When deactivating, the motors are stopped before the contactors cut the drive unit
voltage.
Connecting the manipulator
The motor and resolver signals for respective manipulators motors are gathered in
a common output on the control cabinet and the manipulator is connected to this
output.
- Positioner for station 1 is connected to the output XS101 and
- positioner for station 2 is connected to the output XS102.
Safety
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axes. The function of the
contactors is supervised by the safety equipment.
Working area demarcation
A working area demarcation of the positioners arm is made in software. This is
done to protect the cable harness to external motor from accumulated torsional
stress.
504075-01_en.fm
81
Control Cabinet
Positioner interface
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Lgestllargrnssnitt,
IRBP A
Positioner InterFace,
IRBP A
M2001
11
504 080-880
13
501 111-011
Drivdon
Drive unit
2-axes
14
502 344-001
Kabel DS
Cable DS
Drive system
15
193 715-110
Sockel
Housing
64-pol
16
193 715-607
Ram
Frame
6-mod A-F
W232
19
502 514-880
Kabel
Cable
23
193 751-055
Kontaktor
Contactor
24
193 861-002
Frstrkarblock
Amplifier block
25
193 751-105
Hjlpkontaktblock
26
502 780-002
Trefas kontaktorbygel
27
193 715-707
Modulhllare
Module bracket
28
193 715-708
Modulhllare
Module bracket
29
504 739-880
Byglingsdon
Jumper
39
505 371-880
Anslutningsdon, CombiCon
Conntector, CombiCon
41
504 156-880
Kabelstam + 2 kontaktorer
42
502 338-880
Kabel
Cable
W215-216
43
Kabel
Cable t
W224-225
12-pol.
504075-01_en.fm
Control Cabinet
504075-01_en.fm
29
504075D01-1
15
16
13
14
19
11
43
41
42
27
28
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23
24
25
Positioner interface
83
Control Cabinet
Positioner interface
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OPTION
OPTION
504 746-880
M2001
15
193 715-110
Sockel
Housing
64-pol
16
193 715-607
Ram
Frame
6-mod A-F
24
193 715-152
Kpa
Hood
25
193 715-151
Delad kpa
Shared hood
39
489 947-443
Anslutningsdon, CombiCon
Connector, CombiCon
41
504 159-880
Kabelstam
Cable harness
42
502 508-880
Kabel
Cable
4-pol
W233
504075-01_en.fm
Control Cabinet
39
504746C01
24 15
25 16
42
41
Positioner interface
504075-01_en.fm
85
Control Cabinet
Positioner interface
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504 080-880
11
193 751-055
Kontaktor
Contactor
12
193 861-002
Frstrkarblock
Amplifier block
13
193 751-105
Hjlpkontaktblock
15
500 861-881
16
501 112-001
Digitalt I/O-kort
17
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7-pol
18
500 958-001
Insticksbrygga
Address key
7-pol
20
505 966-880
Seriemtkort, kompl.
Serial measurement
board, compl.
SMB
20.1
505 966-001
Seriemtkort
Serial measurement
board
20.5
505 966-003
Batterienhet
Battery unit
26
500 157-001
Skrmklmma
Clamp
27
193 715-707
Modulhllare
Module bracket
28
193 715-708
Modulhllare
Module bracket
31
502 152-880
Plt kompl.
Plate compl.
41
504 150-880
Kabelstam, 2 akt.enhet
42
502 505-880
Kabel
Cable
W221-223
44
502 341-881
Kabel
Cable
W217
45
502 511-880
Kabel
Cable
W230
46
502 517-880
Kabel
Cable
W231
6-16 mm
504075-01_en.fm
Control Cabinet
Positioner interface
27
28
42
11
12
13
15
26
20
16
17
18
504080D01
46
45
44
504075-01_en.fm
41
87
Control Cabinet
Positioner interface
88
504075-01_en.fm
Control Cabinet
504868-04_en.fm
89
Control Cabinet
503597A1
Connection of an OEM power source requires you to be fully conversant with the
how configuration
of the power source in question should be carried out in the control system.
90
504868-04_en.fm
Control Cabinet
Arcitec
A process control card is used for communication with the robots control system
for control and supervision of the wire-feed system and connected accessories.
504868-04_en.fm
91
Control Cabinet
4.3 Connection
The cable harness to external equipment is connected to the output on the left-hand
side of the top cabinet or to jackable terminals mounted internally by the two-piece
cable gland.
6
5
4
7
1
Output 2
Figure 17 Connection
92
Power source
Mechanical cleaner
504868-04_en.fm
Control Cabinet
503270
Power supply
The following voltages are available on the jackable terminal A202-X3:
503270-01_en.fm
115V AC
230V AC
93
Control Cabinet
Auto stop
General stop
External motors on
The following emergency stop signals are available on the jackable terminal A202-X1:
CAN-bus
The terminated CAN bus channel A202-TB2 can be used, e.g. for the connection
of extra I/O cards.
94
503270-01_en.fm
Control Cabinet
503270-01_en.fm
95
Control Cabinet
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Processutrustning,
NO PROC IF
Process device,
NO PROC IF
489 947-451
Anslutningsdon, CombiCon
Connector, CombiCon
12 pol
489 947-447
Anslutningsdon, CombiCon
Connector, CombiCon
8 pol
502 796-881
CANBUS-terminering
hona
CAN-bus termination
female
193 817-003
ndhylsa
End sleeve
418 883-006
Kabelkanal
Cable trunking
489 327-025
Skruv
Screw
M5X8
2126 011-09
Mutter
Nut
M8
2195 013-11
Bricka
Washer
502 940-087
Enledarkabel
Single core
1.0
503270-01_en.fm
Control Cabinet
503270A01
503270-01_en.fm
97
Control Cabinet
98
503270-01_en.fm
Control Cabinet
4
3
PIB
Main contactor
Interlock relays
Signal connection
Transformer
The interface is fitted with internal wiring for connection to the robot control
system.
502784-01_en.fm
99
Control Cabinet
5
4
1
Output 2
Power source
TCP tool
Mechanical cleaner
Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/42(28)/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 42V AC and
the rectifier part on the process control card with 28V AC.
100
502784-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
systems panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.
502784-01_en.fm
101
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 19 Emergency stop loop with the addition "Extended emergency stop function"
102
502784-01_en.fm
Control Cabinet
Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"
502784-01_en.fm
103
Control Cabinet
PIB/node 30
I/O/node 21
SIB/node 8
TB5/M
TB5/F
TB6/M
TB6/F
X5/M
X5/F
Termination
unit
Customer
connection
CAN1.
2
X6/F
X6/M
X7/F
X7/M
X8/M
CAN2
CAN1.
3
I/O/node 10 ...
X5/F
X5/M
X5/F
CAN1.
1
X4/M
X4/F
X15/M
X15/F
A82
(Connector Board)
Termination
unit
X5/M
X5/F
501700A01
The control card houses the hardware and software for control and regulation of
the arc welding equipment.
104
502784-01_en.fm
Control Cabinet
502784-01_en.fm
The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.
Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the lefthand side, inside the top cabinet.
See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
105
Control Cabinet
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502 784-880
Processutrustning
Process equipment
502 501-880
436 829-009
Jordklmma
Clamp
$QPlUNQLQJDU
5HPDUNV
LAW/RPA
2126 011-09
Mutter
Nut
2195 013-11
Bricka
Washer
M8
418 159-020
Tcklock flns
8+12 pol
418 159-019
Tcklock flns
19+23 pol
489 327-012
Skruv
Screw
M3X12
2126 011-03
Mutter
Nut
M3
193 715-152
Kpa
Hood
10
193 715-151
Shared hood,max 4
cables
11
193 715-167
Blindpropp
Blind plug
12
489 327-019
Skruv
Screw
M4x12
13
192 230-110
Blindpropp
Blind plug
D=20
14
503 260-880
W240
502784-01_en.fm
Control Cabinet
3/4
14
9/10/11/12
502784A01
5/7/8/13
502784-01_en.fm
6/7/8/12
107
Control Cabinet
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108
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193 751-055
Kontaktor
Contactor
193 861-002
Frstrkarblock
Amplifier block
193 751-105
Hjlpkontaktblock
500 861-881
Skerh.rel kompl.2vxl
501 700-880
PIB
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7pol
500 958-001
Insticksbrygga
Address key
7-pol
501 714-001
418 883-006
Kabelkanal
Cable trunking
10
489 327-025
Skruv
Screw
M5X8
11
502 777-880
Kabelstam
Cable harness
12
503 251-880
W241
13
503 254-880
W242
14
503 257-880
Kabel, BullsEye/TC
Cable, BullsEye/TC
W243
502784-01_en.fm
Control Cabinet
8
4
1/2/3
11
6/7
9/10
13
12
502501A01
14
502784-01_en.fm
109
Control Cabinet
110
502784-01_en.fm
Control Cabinet
4.8 MILLER
There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.
4
3
PIB
Main contactor
Interlock relays
Signal connection
Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.
502786-01_en.fm
111
Control Cabinet
20
19
18
17
16
15
14
1
20
13
12
11
10
2
20
20
Output 2
8
7
20
3
5
112
1. Positioner
2. Conveyor motor/resolver
3. Operators panel
6. Power source
7. Wire cutter
8. TCP tool
9. Mechanical cleaner
20. Spare
502786-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
systems panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.
502786-01_en.fm
113
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 22 Emergency stop loop with the addition "Extended emergency stop function"
114
502786-01_en.fm
Control Cabinet
Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"
502786-01_en.fm
115
Control Cabinet
&$1EXV&RQQHFWLRQ/$:53$
PIB/node 30
I/O/node 21
SIB/node 8
TB5/M
TB5/F
TB6/M
TB6/F
X5/M
X5/F
Termination
unit
Customer
connection
CAN1.
2
X6/F
X6/M
X7/F
X7/M
X8/M
CAN2
CAN1.
3
I/O/node 10 ...
X5/F
X5/M
CAN1.
1
X4/M
X4/F
X15/M
X15/F
A82
(Connector Board)
Termination
unit
X5/M
X5/F
X5/F
Figure 24 CAN-bus
116
502786-01_en.fm
Control Cabinet
501700A01
The control card houses the hardware and software for control and regulation of
the arc welding equipment.
502786-01_en.fm
117
Control Cabinet
118
The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.
Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the lefthand side, inside the top cabinet.
See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
502786-01_en.fm
Control Cabinet
502786-01_en.fm
119
Control Cabinet
3RVLWLRQV
QXPPHU
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502 786-880
Processutrustning
Process equipment
MILLER
502 503-880
436 829-009
Jordklmma
Clamp
2126 011-09
Mutter
Nut
2195 013-11
Bricka
Washer
418 159-020
Tcklock flns
418 159-019
Tcklock flns
19+23 pol
489 327-012
Skruv
Screw
M3X12
2126 011-03
Mutter
Nut
M3
M8
8+12 pol
193 715-152
Kpa
Hood
10
193 715-151
11
193 715-167
Blindpropp
Blind plug
12
489 327-019
Skruv
Screw
M4X12
13
192 230-110
Blindpropp
Blind plug
D=20
14
503 260-880
W240
502786-01_en.fm
Control Cabinet
5/7/8/12/13
3/4
6/7/8/12
14
502786
9/10/11/12
502786-01_en.fm
121
Control Cabinet
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122
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$QPlUNQLQJDU
5HPDUNV
193 751-055
Kontaktor
Contactor
193 861-002
Frstrkarblock
Amplifier block
193 751-105
Hjlpkontaktblock
500 861-881
Skerh.rel kompl.2vxl
501 700-881
PIB
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7pol
500 958-001
Insticksbrygga
Address key
7-pol
501 714-002
418 883-006
Kabelkanal
Cable trunking
10
489 327-025
Skruv
Screw
11
502 777-880
Kabelstam proc
M5X8
12
503 251-880
W241
13
503 254-880
W242
14
503 257-880
Cable to Bullseye/TC
W243
502786-01_en.fm
Control Cabinet
8
4
1/2/3
11
6/7
9/10
5
14
13
502503A01
12
502786-01_en.fm
123
Control Cabinet
124
502786-01_en.fm
Control Cabinet
4
3
PIB
Main contactor
Interlock relays
Signal connection
Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.
502785-01_en.fm
125
Control Cabinet
20
20
20
20
Output 2
4
5
9
8
20
126
502785-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
systems panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.
502785-01_en.fm
127
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 26 Emergency stop loop with the addition "Extended emergency stop function"
128
502785-01_en.fm
Control Cabinet
Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"
502785-01_en.fm
129
Control Cabinet
&$1EXV&RQQHFWLRQ/5%
SLRB/eipaw
XP4/M
XS4/F
PIB/node 30
Termination
unit
Burnd
y 12pol
X6/F
X6B/M
TB5/M
TB5/F
I/O/node 21
SIB/node 8
TB6/M
TB6/F
X5/M
X5/F
Customer
connection
X6/F
X6/M
CAN1.
2
X7/F
X7/M
X8/M
CAN2
CAN1.
3
I/O/node 10 ...
X5/F
X5/M
X5/F
CAN1.
1
X4/M
X4/F
X15/M
X15/F
A82
Connector Board
Termination
unit
X5/M
X5/F
Figure 28 CAN-bus
130
502785-01_en.fm
Control Cabinet
501700A01
The control card houses the hardware and software for control and regulation of
the arc welding equipment.
The cables for the supply voltage are connected to the control cabinets
main power switch.
Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.
See the separate manual in the section Power Source for a description of
included welding power sources.
502785-01_en.fm
131
Control Cabinet
The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.
Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the lefthand side, inside the top cabinet
- See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
132
502785-01_en.fm
Control Cabinet
502785-01_en.fm
133
Control Cabinet
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502 785-880
Processutrustning
Process equipment
502 501-880
Gem. detaljer fr
matarverk 42V
436 829-009
Jordklmma
Clamp
500 861-881
Skerh.rel kompl.2vxl
2126 011-09
Mutter
Nut
$QPlUNQLQJDU
5HPDUNV
LRB
M8
2195 013-11
Bricka
Washer
418 159-019
Tcklock flns
19+23 pol
489 327-012
Skruv
Screw
M3X12
2126 011-03
Mutter
Nut
M3
193 715-152
Kpa
Hood
10
193 715-151
Shared hood,max 4
cables
11
193 715-167
Blindpropp
Blind plug
12
489 327-019
Skruv
Screw
M4X12
13
193 715-159
Kabel ttning
Cable gland
D=9-10mm
14
502785-01_en.fm
Control Cabinet
4/5
14
9/10/11/12/13
502785A01
6/7/8/12
502785-01_en.fm
135
Control Cabinet
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193 751-055
Kontaktor
Contactor
193 861-002
Frstrkarblock
Amplifier block
193 751-105
Hjlpkontaktblock
500 861-881
Skerh.rel kompl.2vxl
501 700-880
PIB
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7pol
500 958-001
Insticksbrygga
Address key
7-pol
501 714-001
418 883-006
Kabelkanal
Cable trunking
10
489 327-025
Skruv
Screw
M5X8
11
502 777-880
Kabelstam
Cable harness
12
503 251-880
W241
13
503 254-880
W242
14
503 257-880
Kabel, BullsEye/TC
Cable, BullsEye/TC
W243
502785-01_en.fm
Control Cabinet
8
4
1/2/3
11
6/7
9/10
13
12
502501A01
14
502785-01_en.fm
137
Control Cabinet
138
502785-01_en.fm
Control Cabinet
4
3
PIB
Main contactor
Interlock relays
Signal connection
Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.
503360-01_en.fm
139
Control Cabinet
20
19
18
17
16
15
14
1
20
13
12
11
10
2
20
20
Output 2
8
7
20
3
5
140
1. Positioner
2. Conveyor motor/resolver
3. Operators panel
6. Power source
7. Wire cutter
8. TCP tool
9. Mechanical cleaner
20. Spare
503360-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
systems panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.
503360-01_en.fm
141
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 30 Emergency stop loop with the addition "Extended emergency stop function"
142
503360-01_en.fm
Control Cabinet
Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"
503360-01_en.fm
143
Control Cabinet
XP4/M
XS4/F
Burnd
y 12pol
Termination
unit
XP107/M
XS107/F
PIB/node 30
I/O/node 21
SIB/node 8
Burnd
y
X5/M
X5/F
TB6/M
TB6/F
X6/F
X6B/M
TB5/M
TB5/F
Customer
connection
CAN1.
2
X6/F
X6/M
X7/F
X7/M
CAN2
CAN1.
3
I/O/node 10 ...
X5/F
X5/M
X5/F
CAN1.
1
X4/M
X4/F
X8/M
X15/M
X15/F
A82
Connector Board
Termination
unit
X5/M
X5/F
Figure 32 CAN-bus
144
503360-01_en.fm
Control Cabinet
501700A01
The control card houses the hardware and software for control and regulation of
the arc welding equipment.
Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.
See the separate manual in the section Power Source for a description of
included welding power sources.
503360-01_en.fm
145
Control Cabinet
The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.
Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the lefthand side, inside the top cabinet
See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
- A cooling unit is required if a water cooled gun is included.
- The cable from the cooling unit is inserted through the two-piece cover
and is connected to the jackable terminal X202 located on the left-hand
side, inside the top cabinet
- See the separate manual under section "Cooling unit" for a description of
the cooling unit.
146
503360-01_en.fm
Control Cabinet
503360-01_en.fm
147
Control Cabinet
3RVLWLRQV
QXPPHU
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503 360-880
Processutrustning
Process equipment
LRC
502 501-880
436 829-009
Jordklmma
Clamp
500 861-881
Skerh.rel kompl.2vxl
2126 011-09
Mutter
Nut
2195 013-11
Bricka
Washer
418 159-020
Tcklock flns
8+12 pol
418 159-019
Tcklock flns
19+23 pol
489 327-012
Skruv
Screw
M3X12
2126 011-03
Mutter
Nut
M3
10
193 715-152
Kpa
Hood
11
193 715-151
12
193 715-167
Blindpropp
Blind plug
13
489 327-019
Skruv
Screw
M8
M4X12
14
192 230-110
Blindpropp
Blind plug
D=20
15
193 715-159
Kabel ttning
Cable gland
D=9-10mm
16
17
503 078-881
503360-01_en.fm
Control Cabinet
4/5
17
10/11/12/13/15
16
503360A01
6/8/9/13/14
503360-01_en.fm
7/8/9/13
149
Control Cabinet
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5HPDUNV
193 751-055
Kontaktor
Contactor
193 861-002
Frstrkarblock
Amplifier block
193 751-105
Hjlpkontaktblock
500 861-881
Skerh.rel kompl.2vxl
501 700-880
PIB
489 947-244
Anslutningsdon, CombiCon
Connector, CombiCon
7pol
500 958-001
Insticksbrygga
Address key
7-pol
501 714-001
418 883-006
Kabelkanal
Cable trunking
10
489 327-025
Skruv
Screw
M5X8
11
502 777-880
Kabelstam
Cable harness
12
503 251-880
W241
13
503 254-880
W242
14
503 257-880
Kabel, BullsEye/TC
Cable, BullsEye/TC
W243
503360-01_en.fm
Control Cabinet
8
4
1/2/3
11
6/7
9/10
13
12
502501A01
14
503360-01_en.fm
151
Control Cabinet
152
503360-01_en.fm
Control cabinet
4
3
PIB
Main contactor
Interlock relays
Signal connection
Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.
502891-01_en.fm
153
Control cabinet
20
19
18
17
16
15
14
1
20
13
12
11
10
2
20
20
Output 2
8
7
20
3
5
154
1. Positioner
2. Conveyor motor/resolver
3. Operators panel
6. Power source
7. Wire cutter
8. TCP tool
9. Mechanical cleaner
20. Spare
502891-01_en.fm
Control cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
systems panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.
502891-01_en.fm
155
Control cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 34 Emergency stop loop with the addition "Extended emergency stop function"
156
502891-01_en.fm
Control cabinet
Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"
502891-01_en.fm
157
Control cabinet
&$1EXV&RQQHFWLRQ/5%
SLRB/eipaw
XP4/M
XS4/F
PIB/node 30
Termination
unit
Burnd
y 12pol
X6/F
X6B/M
TB5/M
TB5/F
I/O/node 21
SIB/node 8
TB6/M
TB6/F
X5/M
X5/F
Customer
connection
X6/F
X6/M
CAN1.
2
X7/F
X7/M
X8/M
CAN2
CAN1.
3
I/O/node 10 ...
X5/F
X5/M
X5/F
CAN1.
1
X4/M
X4/F
X15/M
X15/F
A82
Connector Board
Termination
unit
X5/M
X5/F
Figure 36 CAN-bus
158
502891-01_en.fm
Control cabinet
501700A01
The control card houses the hardware and software for control and regulation of
the arc welding equipment.
The cables for the supply voltage are connected to the control cabinets
main power switch.
Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.
See the separate manual in the section Power Source for a description of
included welding power sources.
502891-01_en.fm
159
Control cabinet
The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.
Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the lefthand side, inside the top cabinet
See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
160
502891-01_en.fm
Control cabinet
502891-01_en.fm
161
Control cabinet
3RVLWLRQV
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502 891-880
Process utrustning,
Aluminium
Process equipment,
Aluminium
502 501-880
436 829-009
Jordklmma
Clamp
500 861-881
Skerh.rel kompl.2vxl
2126 011-09
Mutter
Nut
2195 013-11
Bricka
Washer
418 159-020
Tcklock flns
8+12 pol
418 159-019
Tcklock flns
19+23 pol
489 327-012
Skruv
Screw
M3X12
M3
162
$QWDO
4XDQWLW\
7 kg
M8
2126 011-03
Mutter
Nut
10
193 715-152
Kpa
Hood
11
193 715-151
12
193 715-167
Blindpropp
Blind plug
13
489 327-019
Skruv
Screw
M4X12
14
192 230-110
Blindpropp
Blind plug
D=20
15
193 715-159
Kabel ttning
Cable gland
D=9-10mm
16
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Skerh.rel kompl.2vxl
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PIB
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Anslutningsdon, CombiCon
Connector, CombiCon
7pol
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Address key
7-pol
501 714-001
418 883-006
Kabelkanal
Cable trunking
10
489 327-025
Skruv
Screw
M5X8
11
502 777-880
Kabelstam
Cable harness
12
503 251-880
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503 254-880
W242
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503 257-880
Kabel, BullsEye/TC
Cable, BullsEye/TC
W243
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Connector, CombiCon
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End bracket
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Screw
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503 087-880
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Control Cabinet
504868-05_en.fm
169
Control Cabinet
170
504868-05_en.fm
Control Cabinet
7
5
8
2
3
6
4
Figure 37 Traditional welding robot station
1
2
3
4
5
Robot
Positioner
Operator panel
Light barriers
Supervised area station 1
504868-05_en.fm
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7
8
9
171
Control Cabinet
504000-7
7
3
1
2
3
4
172
Robot
Positioner
Operator panel
Light barriers
5
6
7
8
Supervised area
Supervised programming area
Barrier
Service door
504868-05_en.fm
Control Cabinet
5.3 Connections
The cable harness to external equipment is connected to the output on the left-hand
side of the top cabinet or to jackable terminals mounted internally by the two-piece
cable gland.
5.3.1 General
1
2
3
4
8
9
10
11
12
13
14
15
Uttag2
1
2
3
4
5
6
7
8
9
Gate switch
Gate reset
Home position/transport indicator
Position indicator for robot/travel
track
Roller door station 1
Roller door station 2
Operator panel
Activation unit working area 2
Timer resetting station 2/ Light
curtain station 2
504868-05_en.fm
173
Control Cabinet
174
504868-05_en.fm
Control Cabinet
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504771-01_en.fm
175
Control Cabinet
1
2
3
8
7
6
Uttag2
Figure 40 Connections
Gate switch
Operator panel
Gate reset
Light barrier 1
Spare
Power supply
The safety equipment is fed with 24V DC from an internal supply unit (24V I/O).
The supply to external safety components is fuse protected internally on the circuit
card for safety supervision and may be loaded with max. 1.5 A continuously.
176
504771-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operators panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.
504771-01_en.fm
177
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 42 Emergency stop loop with the addition "Extended emergency stop function"
178
504771-01_en.fm
Control Cabinet
runchain
For detailed information about the design of the operating stop loop refer to the
"The robots Users Manual"
Two channel break up of the operating stop loops takes place using the circuit card
for safety supervision and the gate switch.
The safety functions on the circuit card are connected to the:
- "GENERAL STOP"
The gate switch is connected to the:
- "AUTO STOP".
In order to run the robot and positioner in the "AUTO" operating mode requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
Operation of the positioners station switching unit and work station in the
supervised area is not permitted in the MAN FS (Mode MANUAL - Full speed)
operating mode.
504771-01_en.fm
179
Control Cabinet
4
Figur 44 Safety module with option card.
1
2
180
Safety module
Option card
3
4
Connection
Enclosure
504771-01_en.fm
Control Cabinet
6
3
5
Figur 45 Module for safety surveillance.
1
2
3
4
Safety relays
DIL switch
Internal connections
External connections
5
6
7
8
Fuse
Voltage regulator
Voltage regulator
CAN-processor
The safety functions can be expanded using different option cards connected to the
circuit card depending on the selected station solution.
504771-01_en.fm
181
Control Cabinet
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504771-01_en.fm
Control Cabinet
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SUPPLY TO STD
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24V
0V
SUPPLY TO ADDITIONAL
SAFETY EQUIPMENT
24V
0V
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Figure 50 Entry protection with relay outputs. The status shown with active protection.
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Figure 51 Entry protection with limit switch. The status shown with active protection.
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Figure 54 Entry protection with one PNP-output and one INVERTED PNP-output
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Figure 55 Entry protection with one NC and one NO-output. The status shown with active protection
(relay or limit switch)
190
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INPUT
HATCH IS
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INPUT
HATCH IS
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OUTPUT
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TEST INPUT
Figure 58 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 1/2.
24V
24V
B2
B2
0V
0V
A2
A2
ADDITIONAL SAFETY OUTPUTS
7%
15
16
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15
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TEST INPUT
AREA 1
TEST INPUT
AREA 2
Figure 59 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 3.
Resetting of the protected outputs on the SIB V module will fail if a fault occurs on
any of the relays.
504771-01_en.fm
193
Control Cabinet
the operator closes the door, for example, after program adjustment and
194
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Figure 61 Service door with the limit switch - manual resetting of the protection
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Control Cabinet
Station 2
Station 1
Robot
Limit Switch
Figure 64 Example of station indication on a positioner with a station switching unit and two stations.
Connection
This function is only included on SIB V module types 1 and 2.
Signals from limit switch on the positioner are pre-routed to a jackable terminal on
the safety module.
The terminal can be connected directly to the SIB V module on output TB2. The
signals are utilised by the safety circuits, which activate the control systems
operating loop.
504771-01_en.fm
201
Control Cabinet
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A
24V
24V
0V
INPUT
STN A
AT IRB
0V
INPUT
STN B
AT IRB
6,%
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A1
10
A2
11
B1
12
B2
Figure 65 Supervision of the positioners movement and station indication with a 2-station solution
202
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326,7,21(5,17(5&+$1*(683(59,6,21
A
24V
24V
0V
24V
0V
24V
0V
INPUT
STN C
AT IRB
INPUT
STN B
AT IRB
INPUT
STN D
AT IRB
0V
6,%
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10
A1
A2
11
B1
12
B2
13
C1
14
C2
15
D1
16
D2
Figure 66 Supervision of the positioners movement and station indication with a 3/4-station solution
"NOTE!
Equipment used to monitor positioner movement and to indicate the station side
(inputs A - D in the fugures above), should be designed so it cannot switch on the
safety inputs on the SIB V module in the event of a fault arising."
Resetting
The signals from the safety switch are connected to double supervised safety inputs
on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection is carried out as shown in the example.
Testing
The safety circuit is designed so that:
- the limit switch and the input circuits are checked and reset automatically with station switching before a new working cycle is started.
504771-01_en.fm
203
Control Cabinet
Robot
Limit Switch
Station 1
Station 2
Figure 67 Example station indication on the robot with two work stations.
When the limit switches are mounted on the base of the robot these are activated
by a common cam rod.
The switch function results in:
- station indication
- a supervised service position, where the robot can be set, for example,
for cleaning the tool. This area is permanently linked to the 0-position
for the robots axis 1 and permits a movement of 7.
Robot
Limit Switch
Station 1
Station 2
Service position
Figure 68 Example service position for a robot with two work stations.
204
504771-01_en.fm
Control Cabinet
Limit Switch
Robot
Station 1
Conveyor
Station 2
Figure 69 Example 3 Station indication on the conveyor for the robot with two work stations.
Depending on the selected station solution, the switches can also be mounted on
the base of the robot when a conveyor is included.
504771-01_en.fm
205
Control Cabinet
24V
;
24V
0V
13
14
15
0V
6,%
7%
12
A1
A2
B1
B2
206
504771-01_en.fm
Control Cabinet
Robot
Home position
Station 1
Figure 71 Example home position for the robot with one work station
Robot
Limit Switch
Conveyor
Station 1
Station 2
Safety switches are mounted on the base of the robot. They are actuated by an
adjustable cam rod that permits a movement of the robots axis 1 by 20 in the
safe position.
The area can be adjusted by 30 interval around the robots axis 1.
504771-01_en.fm
207
Control Cabinet
;
24V
0V
6,%
7%
Figure 73 Supervision of the home position/transport position with the limit switch
208
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Control Cabinet
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209
Control Cabinet
;;
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MAN FS
6,%
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TO RESET RELAY
GUARD EQ.
Figure 74 The activation push-button for programming from the operators area
210
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24V
AS2+
GS2-
0V
AS1-
6,%
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A
SAFETY FUNCT.
GENERAL STOP CH.1
SAFETY FUNCT.
SAFETY FUNCT.
AUTO STOP CH.1 GENERAL STOP CH.2
B
SAFETY FUNCT.
AUTO STOP CH.2
504771-01_en.fm
211
Control Cabinet
GENERAL
STOP
AUTO
STOP
V-SUPPLY
6,%
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ICH.
POS.
GUARD
EQ.
LOAD
STN.
MODE
SEL. SW.
SERVICE
DOOR
ICH.
UNIT
Figure 76 The safety functions design for the safety module SIB-V type 1/2
GENERAL
STOP
AUTO
STOP
V-SUPPLY
6,%
7%
AREA 2
HOME /
TRANSP.
POS.
IRB/RTT
POS.
AREA 1
HOME /
TRANSP.
POS.
IRB/RTT
POS.
GUARD
EQ.
SERVICE
DOOR
LOAD
STN.
GUARD
EQ.
LOAD
STN.
Figure 77 The safety functions design for the safety module SIB-V type 3
212
504771-01_en.fm
Control Cabinet
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS *)
6,%
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10
11
GSTOP
CH.1
12
15
16
17
GSTOP
CH.2
GSTOP
CH.1
18
GSTOP
CH.2
Figure 78 The break-out points for the operating loop safety module SIB-V type 1/2
In Figure 79 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V-module type 3 and some examples of how these can be used are
also shown.
OPTIONAL FUNCT.
IN PARALLELL
WITH IRB/RTT POS /
LOAD STN - AREA1
6,%
7%
GSTOP
CH.1
GSTOP
CH.1
GSTOP
CH.1
GSTOP
CH.2
GSTOP
CH.2
10
11
12
GSTOP
CH.2
Figure 79 The break-out points for the operating loop safety module SIB-V type 3
504771-01_en.fm
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GSTOP
CH.1
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS
17
18
7%
GSTOP
CH.2
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS
AREA 1
CH.A
AREA 1
CH.B
Figure 80 Examples of connecting the entry protection between the programming area.
214
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CH.1
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10
11
12
GSTOP
CH.2
AREA 1
CH.A
AREA 2
CH.A
AREA 1
CH.B
AREA 2
CH.B
Figure 81 Examples of connecting entry protection between operator area 1 and operator area 2.
504771-01_en.fm
215
Control Cabinet
ACTIVATE
AREA 1
ACTIVATE
AREA 2
6,%
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AREA 1
CH.A
AREA 1
CH.B
STN 1
STN 2
10
STN 3*)
11
12
STN 4*)
Figure 83 Safety outputs for safety module SIB-V type 1/2, max. 2 A
216
504771-01_en.fm
Control Cabinet
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STN 1
AREA 1
CH.B
CH.A
10
11
AREA 2
CH.A
STN 2
12
AREA 2
CH.B
PNEUM. VALVE
AIR SUPPLY
STN1
PNEUM. VALVE
AIR SUPPLY
STN2
SAFETY RELAYS
B
B
B
A
A
7%
7%
15
16
EM.
STOP
CH.B
TEST INPUT
EM.
STOP
CH.A
STN 2
7%
1
In1
2
On2
STN 1
On1
AREA 1
CH.B
In2
AREA 1
CH.A
OUTPUT(S)
CLAMP
VALVE(S)
STN 1
OUTPUT(S)
CLAMP
VALVE(S)
STN 2
Figure 85 Example of the fixture interlock principle with safety module SIB-V type 1
504771-01_en.fm
217
Control Cabinet
PNEUM. VALVE
AIR SUPPLY
STN1
PNEUM. VALVE
AIR SUPPLY
STN2
SAFETY RELAYS
1B
1A
2B
2A
1B
2B
1A
2A
6,%
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AREA 1
CH.A
STN 1
AREA 1
CH.B
10
AREA 2
CH.A
STN 2
INPUT
ACTIVATE
CLAMP
VALVES
STN 1
7%
INPUT
ACTIVATE
CLAMP
VALVES
STN 2
EM.
STOP
CH.B
EM.
STOP
CH.A
TEST INPUT
7%
1B
2B
1A
2A
In2
In1
12
AREA 2
CH.B
TEST INPUT
7%
11
2
On2
On1
7%
OUTPUT(S)
CLAMP
VALVE(S)
STN 1
OUTPUT(S)
CLAMP
VALVE(S)
STN 2
Figure 86 Example of the fixture interlock principle with safety module SIB-V type 3
218
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17
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Connector, Combicon
7 pol
18
500 958-001
Insticksbrygga
Bridge
7 pol
20
436 829-009
Jordklmma
Terminal
41
502 291-880
Kabelstam
Cable harness
504771-01_en.fm
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Control Cabinet
20
504771a01
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18
41
11
15
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504771-01_en.fm
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222
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skpinsida.jpg
Figure 87
504773-01_en.fm
223
Control Cabinet
8
9
10
11
12
13
14
15
Uttag2
Figure 88 Connections
1
2
3
4
5
6
7
8
9
Gate switch
Gate reset
Home position/transport indicator
Position indicator for robot/travel
track
Roller door station 1
Roller door station 2
Operator panel
Activation unit working area 2
Timer resetting station 2/ Light
curtain station 2
Power supply
The safety equipment is fed with 24V DC from an internal supply unit (24V I/O).
The supply to external safety components is fuse protected internally on the circuit
card for safety supervision and may be loaded with max. 1.5 A continuously.
224
504773-01_en.fm
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operators panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.
504773-01_en.fm
225
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 90 Emergency stop loop with the addition "Extended emergency stop function"
226
504773-01_en.fm
Control Cabinet
runchain
For detailed information about the design of the operating stop loop refer to the
"The robots Users Manual"
Two channel break up of the operating stop loops takes place using the circuit card
for safety supervision and the gate switch.
The safety functions on the circuit card are connected to the:
- "GENERAL STOP"
The gate switch is connected to the:
- "AUTO STOP".
In order to run the robot and positioner in the "AUTO" operating mode requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
Operation of the positioners station switching unit and work station in the
supervised area is not permitted in the MAN FS (Mode MANUAL - Full speed)
operating mode.
504773-01_en.fm
227
Control Cabinet
4
Figur 92 Safety module with option card.
1
2
228
Safety module
Option card
3
4
Connection
Enclosure
504773-01_en.fm
Control Cabinet
6
3
5
Figur 93 Module for safety surveillance.
1
2
3
4
Safety relays
DIL switch
Internal connections
External connections
5
6
7
8
Fuse
Voltage regulator
Voltage regulator
CAN-processor
The safety functions can be expanded using different option cards connected to the
circuit card depending on the selected station solution.
504773-01_en.fm
229
Control Cabinet
6,%
7%
24V
0V
6,%
7%
230
504773-01_en.fm
Control Cabinet
7%
24V
0V
SUPPLY TO STD
SAFETY EQUIPMENT
24V
0V
SUPPLY TO ADDITIONAL
SAFETY EQUIPMENT
24V
0V
6,%
7%
24V
0V
504773-01_en.fm
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Control Cabinet
232
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Figure 98 Entry protection with relay outputs. The status shown with active protection.
504773-01_en.fm
233
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Figure 99 Entry protection with limit switch. The status shown with active protection.
234
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n*)
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0V
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A
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0V
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Figure 101 Entry protection with one PNP-output and one NPN-output
236
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n*)
n*)
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B
Figure 102 Entry protection with one PNP-output and one INVERTED PNP-output
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Control Cabinet
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n*)
n*)
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6,%
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B
Figure 103 Entry protection with one NC and one NO-output. The status shown with active protection
(relay or limit switch)
238
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Control Cabinet
*8$5'(48,30 02725+$7&+
24V
0V
INPUT
HATCH IS
UP
INPUT
HATCH IS
DOWN
OUTPUT
HATCH UP
On2
On1
In2
;;
In1
OUTPUT
HATCH
DOWN
24V
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RESET SAFETY
n*)
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Control Cabinet
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24V I/O
PB 1
PB 2
6,%
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ACTIVATE
AREA 1
ACTIVATE
AREA2 *)
240
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Control Cabinet
6,%
7%
17
18
15
16
TEST INPUT
Figure 106 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 1/2.
24V
24V
B2
B2
0V
0V
A2
A2
ADDITIONAL SAFETY OUTPUTS
7%
15
16
7%
15
16
TEST INPUT
AREA 1
TEST INPUT
AREA 2
Figure 107 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 3.
Resetting of the protected outputs on the SIB V module will fail if a fault occurs on
any of the relays.
504773-01_en.fm
241
Control Cabinet
the operator closes the door, for example, after program adjustment and
242
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Control Cabinet
6(59,&('225683(59,6,21
;
n*)
n*)
n*)
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6,%
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ASTOP-
ASTOP+
7%[
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Control Cabinet
244
504773-01_en.fm
Control Cabinet
;
24V
;
24V
0V
6,%
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B
7%
n*)
ASTOP-
n*)
ASTOP+
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Figure 109 Service door with the limit switch - manual resetting of the protection
504773-01_en.fm
245
Control Cabinet
246
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Control Cabinet
5(6(73527(&7,21 35(5(6(7
;;
24V
6,%
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n*)
RES. PROT. IN
n*)
RES. PROT. OUT
7%[
504773-01_en.fm
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Control Cabinet
NO JUMPER
CONNECTION!
6,%
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RES. PROT. IN
n*)
248
504773-01_en.fm
Control Cabinet
Station 2
Station 1
Robot
Limit Switch
Figure 112 Example of station indication on a positioner with a station switching unit and two stations.
Connection
This function is only included on SIB V module types 1 and 2.
Signals from limit switch on the positioner are pre-routed to a jackable terminal on
the safety module.
The terminal can be connected directly to the SIB V module on output TB2. The
signals are utilised by the safety circuits, which activate the control systems
operating loop.
504773-01_en.fm
249
Control Cabinet
326,7,21(5,17(5&+$1*(683(59,6,21
A
24V
24V
0V
INPUT
STN A
AT IRB
0V
INPUT
STN B
AT IRB
6,%
7%
A1
10
A2
11
B1
12
B2
Figure 113 Supervision of the positioners movement and station indication with a 2-station solution
250
504773-01_en.fm
Control Cabinet
326,7,21(5,17(5&+$1*(683(59,6,21
A
24V
24V
0V
24V
0V
24V
0V
INPUT
STN C
AT IRB
INPUT
STN B
AT IRB
INPUT
STN D
AT IRB
0V
6,%
7%
10
A1
A2
11
B1
12
B2
13
C1
14
C2
15
D1
16
D2
Figure 114 Supervision of the positioners movement and station indication with a 3/4-station solution
"NOTE!
Equipment used to monitor positioner movement and to indicate the station side
(inputs A - D in the fugures above), should be designed so it cannot switch on the
safety inputs on the SIB V module in the event of a fault arising."
Resetting
The signals from the safety switch are connected to double supervised safety inputs
on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection is carried out as shown in the example.
Testing
The safety circuit is designed so that:
- the limit switch and the input circuits are checked and reset automatically with station switching before a new working cycle is started.
504773-01_en.fm
251
Control Cabinet
Robot
Limit Switch
Station 1
Station 2
Figure 115 Example station indication on the robot with two work stations.
When the limit switches are mounted on the base of the robot these are activated
by a common cam rod.
The switch function results in:
- station indication
- a supervised service position, where the robot can be set, for example,
for cleaning the tool. This area is permanently linked to the 0-position
for the robots axis 1 and permits a movement of 7.
Robot
Limit Switch
Station 1
Station 2
Service position
Figure 116 Example service position for a robot with two work stations.
252
504773-01_en.fm
Control Cabinet
Limit Switch
Robot
Station 1
Conveyor
Station 2
Figure 117 Example 3 Station indication on the conveyor for the robot with two work stations.
Depending on the selected station solution, the switches can also be mounted on
the base of the robot when a conveyor is included.
504773-01_en.fm
253
Control Cabinet
24V
;
24V
0V
13
14
15
0V
6,%
7%
12
A1
A2
B1
B2
254
504773-01_en.fm
Control Cabinet
Robot
Home position
Station 1
Figure 119 Example home position for the robot with one work station
Robot
Limit Switch
Conveyor
Station 1
Station 2
Safety switches are mounted on the base of the robot. They are actuated by an
adjustable cam rod that permits a movement of the robots axis 1 by 20 in the
safe position.
The area can be adjusted by 30 interval around the robots axis 1.
504773-01_en.fm
255
Control Cabinet
;
24V
0V
6,%
7%
Figure 121 Supervision of the home position/transport position with the limit switch
256
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Control Cabinet
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257
Control Cabinet
;;
24VMAN /
MAN FS
6,%
7%7%
18
TO RESET RELAY
GUARD EQ.
Figure 122 The activation push-button for programming from the operators area
258
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Control Cabinet
24V
AS2+
GS2-
0V
AS1-
6,%
7%
A
SAFETY FUNCT.
GENERAL STOP CH.1
SAFETY FUNCT.
SAFETY FUNCT.
AUTO STOP CH.1 GENERAL STOP CH.2
B
SAFETY FUNCT.
AUTO STOP CH.2
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259
Control Cabinet
GENERAL
STOP
AUTO
STOP
V-SUPPLY
6,%
7%
ICH.
POS.
GUARD
EQ.
LOAD
STN.
MODE
SEL. SW.
SERVICE
DOOR
ICH.
UNIT
Figure 124 The safety functions design for the safety module SIB-V type 1/2
GENERAL
STOP
AUTO
STOP
V-SUPPLY
6,%
7%
AREA 2
HOME /
TRANSP.
POS.
IRB/RTT
POS.
AREA 1
HOME /
TRANSP.
POS.
IRB/RTT
POS.
GUARD
EQ.
SERVICE
DOOR
LOAD
STN.
GUARD
EQ.
LOAD
STN.
Figure 125 The safety functions design for the safety module SIB-V type 3
260
504773-01_en.fm
Control Cabinet
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS *)
6,%
7%
10
11
GSTOP
CH.1
12
15
16
17
GSTOP
CH.2
GSTOP
CH.1
18
GSTOP
CH.2
Figure 126 The break-out points for the operating loop safety module SIB-V type 1/2
In Figure 127 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V-module type 3 and some examples of how these can be used are
also shown.
OPTIONAL FUNCT.
IN PARALLELL
WITH IRB/RTT POS /
LOAD STN - AREA1
6,%
7%
GSTOP
CH.1
GSTOP
CH.1
GSTOP
CH.1
GSTOP
CH.2
GSTOP
CH.2
10
11
12
GSTOP
CH.2
Figure 127 The break-out points for the operating loop safety module SIB-V type 3
504773-01_en.fm
261
Control Cabinet
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+
A
-
B
6,%
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11
12
GSTOP
CH.1
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS
17
18
7%
GSTOP
CH.2
OPTIONAL FUNCT.
IN SERIAL WITH
SAFETY
FUNCTIONS
AREA 1
CH.A
AREA 1
CH.B
Figure 128 Examples of connecting the entry protection between the programming area.
262
504773-01_en.fm
Control Cabinet
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+
A
-
B
NY
6,%
7%
GSTOP
CH.1
11
12
7%
10
11
12
GSTOP
CH.2
AREA 1
CH.A
AREA 2
CH.A
AREA 1
CH.B
AREA 2
CH.B
Figure 129 Examples of connecting entry protection between operator area 1 and operator area 2.
504773-01_en.fm
263
Control Cabinet
ACTIVATE
AREA 1
ACTIVATE
AREA 2
Figure 130 Safety outputs for acknowledgement of entry protection resetting, max. 50 mA
6,%
7%
AREA 1
CH.A
AREA 1
CH.B
STN 1
STN 2
10
STN 3*)
11
12
STN 4*)
Figure 131 Safety outputs for safety module SIB-V type 1/2, max. 2 A
264
504773-01_en.fm
Control Cabinet
6,%
7%
AREA 1
STN 1
AREA 1
CH.B
CH.A
10
11
AREA 2
CH.A
STN 2
12
AREA 2
CH.B
Figure 132 Safety outputs for safety module SIB-V type 3, max. 2 A
PNEUM. VALVE
AIR SUPPLY
STN1
PNEUM. VALVE
AIR SUPPLY
STN2
SAFETY RELAYS
B
B
B
A
A
7%
7%
15
16
EM.
STOP
CH.B
TEST INPUT
EM.
STOP
CH.A
STN 2
7%
1
In1
2
On2
STN 1
On1
AREA 1
CH.B
In2
AREA 1
CH.A
OUTPUT(S)
CLAMP
VALVE(S)
STN 1
OUTPUT(S)
CLAMP
VALVE(S)
STN 2
Figure 133 Example of the fixture interlock principle with safety module SIB-V type 1
504773-01_en.fm
265
Control Cabinet
PNEUM. VALVE
AIR SUPPLY
STN1
PNEUM. VALVE
AIR SUPPLY
STN2
SAFETY RELAYS
1B
1A
2B
2A
1B
2B
1A
2A
6,%
2
AREA 1
CH.A
STN 1
AREA 1
CH.B
10
AREA 2
CH.A
STN 2
INPUT
ACTIVATE
CLAMP
VALVES
STN 1
7%
INPUT
ACTIVATE
CLAMP
VALVES
STN 2
EM.
STOP
CH.B
EM.
STOP
CH.A
TEST INPUT
7%
1B
2B
1A
2A
In2
In1
12
AREA 2
CH.B
TEST INPUT
7%
11
2
On2
On1
7%
OUTPUT(S)
CLAMP
VALVE(S)
STN 1
OUTPUT(S)
CLAMP
VALVE(S)
STN 2
Figure 134 Example of the fixture interlock principle with safety module SIB-V type 3
266
504773-01_en.fm
Control Cabinet
504773-01_en.fm
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Control Cabinet
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Anslutningsdon, Combicon
Connector, Combicon
7 pol
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436 829-009
Jordklmma
Terminal
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Cable harness
504773-01_en.fm
Control Cabinet
504773a01
20
17
18
41
11
15
504773-01_en.fm
269
Control Cabinet
270
504773-01_en.fm
Control Cabinet
Jumper device emergency stop (Fitted in socket X104 on the left of the
cabinet)
Power supply
The following voltages are available on the jackable terminal A203-TB7:
504774-01_en.fm
271
Control Cabinet
Cabinet_S4Cplus_12
Motors on
Emergency stop
All emergency stop buttons included in the system are as standard connected in
series and directly affect the control systems emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operators panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.
272
504774-01_en.fm
Control Cabinet
emstop
For detailed information about the design of the emergency stop loop refer to the
"The robots Users Manual"
emstopoption
Figure 136 Emergency stop loop with the addition "Extended emergency stop function"
504774-01_en.fm
273
Control Cabinet
runchain
For detailed information about the design of the operating stop loop refer to the
"The robots Users Manual"
274
Auto stop
General stop
504774-01_en.fm
Control Cabinet
504774-01_en.fm
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Control Cabinet
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504774-01_en.fm
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504774-01_en.fm
277
Control Cabinet
278
504774-01_en.fm
Control Cabinet
Technical Data
6 Technical Data
Also refer to the Product Manual for the robot
Weight
Min 25C
Max +42C
Max +70C
Min +5C
Max +45C
Relative humidity
Frequency
48.5 61.Hz
Fuse protection
The following applies for the control cabinet with welding power source
LRB400:
Ntspnning/
Mains voltage
(V)
Skring (Trg) /
Fuse (Slow-blow) 2)
(A)
200
80
220
80
) 400
32 ( 35 )
440
40 ( 50 )
475
40 ( 35 )
500
32 ( 35 )
525
32 ( 35 )
600
32 ( 35 )
504868-06_en.fm
279
Control Cabinet
Technical Data
Protection class
IP54
IP21 welding power source LRB400
280
504868-06_en.fm
Control Cabinet
lifting instructions
min 60 degrees
504868-i_en.fm
281
Control Cabinet
7.4 Connections
Control cabinet_S4Cplus-7
FlexArc
In weld cells of the type FlexArc the connection cable is routed to a 63A IEC inlet,
placed on the cell wall for easy mains connection.
282
.
504868-i_en.fm
Control Cabinet
7.6 Start up
All requisite system software is installed on delivery.
Switch on the main power switch on the control cabinet and the main power
switch on the welding power source if fitted. The main power switch on the
control cabinet normally controls the power supply to all component
modules in the cabinet.
Note! Some power sources supply the process control card with an external
reference voltage, which is why some parts of the control cabinet can be
voltage fed even when the main power switch is in the "OFF" position.
The robot makes a self-test on the hardware and software. This test takes
about 1 minute.
504868-i_en.fm
283
Control Cabinet
284
504868-i_en.fm
Control Cabinet
Maintenance
8 Maintenance
The wrist strap, provided in the cabinet, must be worn when handling the
circuit
cards and other electronics in the control cabinet to prevent ESD damage.
The control system is fully enclosed and the electronics are thereby
protected in a normal workshop environment.
In very dusty and powdery environments the cabinet should, however, be
checked regularly internally. If necessary use a vacuum cleaner.
Clean any filters according to the instructions in the robot's Product Manual
as well as in the power source's Product Manual.
504868-u_en.fm
285
Control Cabinet
Maintenance
286
504868-u_en.fm
504 868-102