Product Manual IRB 6000 SHAB 0007-6 Mg3 | | q Os ABB Robotics Products ASEA BROWN BOVERIABB Product Manual, IRB 6000/M93 SHAB 0007-6/Rev 2 Declaration by the manufacturer Configuration List Description IRB 6000 SHAB 0001-6mRev 2 Safety SHAB 0001-8 Installation IRB 6000. SHLAB 0008-6 ) Installation S3 aussay SHAB 0008-22/Rev 1 Maintenance IRB 6000 SHAB 0005-6 Additional Documents (Option,RSI)The information in this document is subject to change without notice and should not be construed as a ‘commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibilty for any cerors that may appear in this document. Inno event shall ABB Robotics Products AB be liable for incidental or consequential damages ari use of this document or ofthe software and hardware described in this document. 9 from This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB's writen permission, and the contents thereof must not be imparted to a third party nor be used for any ‘unauthorized purpose. Contravention will be prosecuted. ‘Additional copies ofthis document may be obtained from ABB Robotics Products AB at its then current charge. ‘© ABE Robotics Products AB 1993 ‘Aticle number: 3HAB 0007-6 Issued: M93 ‘ABB Robotics Products AB 8-721 68 Vasteras ‘SwedenDescription IRB 6000 3HAB 0001-6/Rev 2 M93 AL ED ED PADDED ABB Robotics Products ASEA BROWN BOVERI‘The information in this document is subject to change without notice and should not be construed as a ‘commitment by ABB Robotics Products AB. ABB Rbotics Products AB assumes no responsibilty for any terrors that may appear in this document. Inno ovent shall ABB Robotics Products AB be liable for incidental or consequential damages arising from Use of this document or of the software and hardware described in this document. ‘This document and parts thereof must not be reproduced or copied without ABB RoboticsProducts AB's writen permission, and the contents thereof must not be imparted to a third party nor be used for any ‘unauthorized purpose. Contravention will be prosecuted. ‘Additional copies of this document may be obtained from ABB Robotics Products AB at is then current charge. ‘© ABB Robotics Products AB 1993 ‘Article number: 3HAB 0001-6/Rev 2 Issue: M83. ‘ABB Robotics Products AB S-721 68 Vaster’s ‘SwedenCONTENTS Chanter Page 1 INTRODUCTION 1 2 BENEFITS 8 3 DESCRIPTION 5 3.1 Manipulator 3.2 Control system 4 OPERATION/PROGRAMMING 13 4.1 Control panel 4.1.1 Remote control 42 Programming unit 4.3. Programming 4.3.1 Program design 4.3.2 Movements 4.3.3 Programmable functions 4.3.4 Editing functions 4.3.5 Manually controlled functions 5 TECHNICAL SPECIFICATION 23 5.1 Features 5.1.1 Performance, basic 5.12 Program capacity 5.1.2.1 Accumulator for serial measurement board 5.13 Signal capacity 5.14 Man - machine communication 5.15 Working range 5.16 Load diagram 5.1.7 Extra load on upper arm 5.1.8 Handlingcapacity at presstending valid for 2.8 PT 5.19 Cycle time presstending for 2.8 PT 5.1.10 Processforces for 2.25 PE-75 5.2. Requirements 5.2.1 Environmental requirements 5.22 Electrical connections 5.3. Physical data, dimensional drawings 5.3.1 Physical data, basic 5.32 Dimensional drawings 54 Standards 6 SPECIFICATION OF ROBOT SYSTEM 49 6.1 Manipulator 62 Control system 63 Accessories, mechanical robot and control system Description TRB 6000RB 6000 Description1 INTRODUCTION IRB 6000 is a robot system adapting its basic 120 kg handling eapacity and 2.4m reach into a variety of new configurations to fit the exact needs of diverse applications. By providing just the right robot for the job, IRB 6000 makes possible the most cost-efficient and effective solutions for a wide variety of spot-welding, material-handling, machine tending and process applications. IRB 6000's basic handling capacity of 120 kg may be increased by replacing the basic wrist with another capable of handling up to 150 kg. The reach is inereased from the basic 2.4 m to 2.8 m or 3 m by slotting in extenders before the wrist. If floor space is limited or a robot working from above is needed, IRB 6000 can be readily shelf mounted. It is then able to reach under itself. Description ‘TRB 6000Description2 BENEFITS IRB 6000 ‘The most distinguishing features are: Reach Handling capacity Working range Reliability Peripheral equipment Integrated medi Control system Reach Since the robot reaches over a whole car body, the robot is very suitable for several process applications where reach is the deciding factor. The basic reach of 2.4 m can be extended to 2.8 and 3.0 m (with 75 kg handling capacity). Handling capacity The basic handling capacity of 120 kg can be increased to 150 kg. Working range ‘The robot working range is very large, especially in its upper and lower sections. ‘The shelft-mounted version is also able to reach under itself. Reliability IRB 6000 is modular. It has fewer parts than any other robot in its class, its, structural elements are all rigid steel castings and all bearings and cables are integrated and enclosed. This robust simplicity, plus AC motors, makes IRB 6000 very reliable. Moreover, should IRB 6000 malfunction, its modular design means that the typical mean time to replace a part is less than 30 minutes. Peripheral equipment Peripheral equipment as well as tooling system, spot welding equipment to TG and ‘track motion are available. For further information contact the local representative. Integrated media ‘The integration is facilitated by pre-engineered solutions, bringing electricity and air through the robot. Integrated media for spot-welding guns are available as an option. Performance IRB 6000's base axis and upper arm/wrist axes provide the speed and ‘aceeleration/deceleration to travel 50 mm in less than 0.3 seconds and 300 mm in 0.7 seconds. Control system ‘The S3 Control System makes use of established features like saftkeys, joystick ‘and the robot-language ARLA for simple and fast programming. The control system can handle one external servo-controlled axis for track motion, tool and Positioner. Description ‘TRB 6000Another important factor is the interface capacity. The S3 Control System has the ability to communicate in several different ways. There are optional digital or analogue 1/Os and an optional computer link to a superior computer. Description3 DESCRIPTION ‘The robot consists of a manipulator and a control unit connected by 2 cables. ‘Various options and variants are available. These are described in detail in chapter 6. ‘The control unit contains the total system electronics, and offers many opportunities for external communication and control of peripheral equipment. Operator communication, programming and manual running is performed via a portable programming unit. Programming can also be performed off-line via a terminal and an ABB Roboties Off-line Programming Package. CONTROL SYSTEM }e-[ External VO) Programming unit Power supply Fig. 3.1 System structure IRB 6000 Description TRB 60003.1 Manipulator Main features are the simple build up and compact design, especially: the minimal body swinging radius the slim arm system, Availability Great effort has been put into making the robot easy to service. Only a few special tools are required. Drive system All motors are brushless, maintenance free AC motors. ‘Measurement system and battery unit ‘The measurement system consists of a resolver on each motor shaft and a measurement board mounted on the robot. ‘The resolver is used for gathering speed and position data. The measurement board reads the resolver feedback signals and generates position information for each axis. ‘The rechargable battery is used for supply back up to the measurement board during power off. This prevents the data regarding the number of turns each resolver has made to be erased due to power failure. The battery is charged continously at power on. ‘This means that the robot may be restarted directly from its present position after a system shut down. Brakes ‘As standard, the robot is supplied with electro-mechanical brakes on all axes. The brakes are applied when they are deenergized. ‘The brakes are automatically applied on emergeney stops, power failure, or when the robot isswitched to MOTOR OFF mode.The brakes are activated after 30 secs (automatic mode) or after 5 min (manual mode) if the robot is idle in MOTOR ON. Note. ‘The time for activation 30 sees (automatic mode) is valid for control program as from rev. 3. Individual brakes can be manually deactivated by switches on the side of the robot. ‘The brakes are maintenance-free. A When the brakes are manually deactivated the robot arm can make a sudden, uncontrolled movement. Balancing system ‘The robot is equipped with a spring system for static balancing of axis 2 and a balancing weight for the third axis. Description TRB 6000Gearboxes All gearboxes are precision engineered and are specially adapted for each axis funetion. Cabling ‘The cabling is highly modularized and is easy to replace as complete units. The cables have been arranged for maximum life. DescriptionMovement pattern ‘The robot's movement pattern can briefly be described as follows (see Fig. 3.2). Axis 1(C) Rotation of the complete manipulator. Axis 2B) Forward and reverse movement of the lower arm. Axis 8 (A) ‘Vertical movement of the upper arm. Axis 4D) Rotation of the complete wrist centre. Axis 5) Bending of wrist around the wrist centre, Axis 6 (P) Rotation of mounting flange (turn disc) 8.2 Movement structure Description TRB 60003.2 Control system Control panel Programming unit Floppy disk unit Winchester memory (option) Duty time counter ‘Main functions for robot operation. All functions for robot operation and programming. Built-in system test. Handles storing/loading of data on floppy disk. Handles storing/loading of data in a mass memory. Recording duty time. Monitor, LCD Additional display of user program and process (Option) messages. Cooling device Cooling of the electronic. Connections Control cable connection, process communication, computer link (option), program printout (option). Cooling device 2) fonitor Mains switch os = ° Control panel Programming unit | S @ Floppy disk unit, Duty time counter Connections Fig 84 Control cabinet ‘The look of the cabinet differs, depending on design Description IRB 6000Eletronic components Computer board ‘System board Digital VO boards (option) Analogue VO boards (option) Power unit Rectifier Supply unit Drive units Control board for external axis (option). Mains transformer * Contains four microprocessors: - Main computer - for overall control. + Servo computer - for control of servo functions and robot movements. + Axis computer - for individual control of robot axes. = VO computer - for control of communication with operator unit, peripheral equipment, host computer (option) and floppy dise unit, * Contains all robot primary memory. * Contains circuits for personal safety functions ~ emergency sto} ~ safe guarded stops; = limit switches; = ete. Digital process communication. Analogue process communication. Contactors for power to the rectifier for the drive units ‘and power for the brakes. ‘Voltage supply to drive units. Stabilized voltage supply to all electronics, and /O and brakes. Power amplification for control of motor torque. One sper drive unit. (Up to 7 units incl. one integrated axis.) Speed reference signal for external drive unit of resolver for 1 external axis. Description TRB 6000 10Process connections (option) ‘The system can handle the following input and output signals from the peripheral equipment: * Digital VO - up to 96 inputs and 96 outputs Requires 1 - 6 digital /O boards (option) * Analogue VO = up to 4 inputs and 4 outputs Requires 1 analogue /O board (option) * Combi vo = 16 digital in- and 16 outputs + 2 analogue outputs Requires 1 AD combi I/O board (option) * Computer communication via RS 232 interface. Requires "Computer link” (option). W/O remote bus for Allen Bradly 1771 RIO link, up to 128 in / 128 out (option) Control signals for 1 external axis Requires one extra board (option). Drive system ‘The drive system, for the robot motors and one integrated axis 7 (option), consists of the following units. * Computer board - for overall control. * Rectifier unit + for power supply to the drive units. Drive unit - receives current references from the computer board. The current references control the power amplifier supplying current to the motor. ‘+ Serial measument board - reads the resolver Control system Manipulator Dri Position Speed Torque _Currentt= Fig. 8.5 AC drive system, robot axes and integrated axis 7. Drive unit for optional external axis is located outside the control system. ‘This drive unit is provided with a speed reference by the control system. ‘Separate drive unit Control cabinet ‘gutside control system Fig. 3.6 Drive system external axis. Description IRB 6000 uwDiagnostics ‘The control characteristis stem has its own built-in diagnostics with the following * Test on start-up: = computer board; programming unit; monitor (option); voltage supply unit; rectifier unit. - location control of /O boards and drive units ‘* During diagnostic running, a red LED on the computer board will switch from continuous light to a flashing light. ‘© Successful diagnostic running indicated by: - no red LEDs on all units; - agreen LED lights up on the computer board. ‘+ Unsuccessful diagnostic running indicated by: - ared LED lights up on the faulty board; - if possible, a fault message appears on the programming unit and on the monitor (option). ‘+ Running of the control system in a special test mode during service, with the following functions: - startup test; - fall test of the UO boards, jumpers included; + test running of the drive units at full voltage; ~ program for cleaning the floppy disk unit read/write heads. Description TRB 6000 124 OPERATION/PROGRAMMING Control panel Using the control panel, operating modes can be selected and the robot can be switched to MOTOR ON or MOTOR OFF. Lamps inside the buttons indicate status and any ‘malfunction. The control panel also includes one of the emergency stop buttons. Lockable switch for selection of operation mode: 7] eo Program run at maximum speed. Cd te Program edit and joystick run is not allowed. MANUAL REDUCED SPEED _, <250 mm/s Programming and program P running with maximum speed 250 mm/s. MANUAL FULL SPEED 100% ‘Test run at maximum speed. MOTOR ON mode pushbutton. MOTOR ON mode is indicated by light inside the button. Indication "External axis not synchronized” by means of a blinking MOTOR OFF light. The robot motors are activated in the MOTOR ON mode. ‘MOTOR OFF mode pushbutton. ‘MOTOR OFF mode is indicated by light inside the button. Indication "ERROR" by means of a blinking MOTOR OFF light. ‘The system is activated in the MOTOR OFF mode but not the robot motors. a Emergency stopbutton. Fig4.1 Control panel Description 3 TRB 60004.1.1 Remote control ‘+ By using the first 8 inputs and outputs on any I/O board the following funetions can be remotely controlled: Control Indication Gnput) output) Run Standby Program start Program stop Synchronization From dise Lamp test Prog. unit lock Error Emergency stop PA D4 Dd be Bd Be D4 Dd be be bt be vee 4.2 Programming unit ‘The programming unit (Fig. 4.2) is connected to the control system by a 10 m eable (extension cable 10 m, total 30 m, option). When not in use, it is placed on a consol on the door of the control system. ‘The programming unit is provided with LED displays and membrane buttons with tactile feedback. The enabling device is located under the emergency stop button. ‘The enabling device allows the operator to switch between MOTOR ON and ‘MOTOR OFF when the operating mode selector is in one of the MANUAL Positions. All operator communications, except selection of the operational mode for the robot, are available on the portable programming unit. The programming unit is, provided with the following facilities for this purpose: + An illuminated two-row alphanumeric display for messages in plain language. ‘The system can display: = texts in any of 10 languages: English, German, French, Dutch, Italian, Spanish, Portuguese, Japanese(Katakana) Finnish and Swedish; + numerical values in metric or imperial. + Five multi-function buttons below the panel. The text on the lower row of the display defines the use of the multi-funetion buttons. + Six to eight menus for most of the system functions, Each menu contains a particular type of function, e.g. program editing. * Joystick ‘The robot and the external axis are positioned using the joystick, together with the safety pad and the switches in the upper right-hand corner. Description TRB 6000 14Fig 4.2 Programming unit 4.3 Programming 4.3.1 Program design ‘The user memory can contain programs numbered from 0 to 9999. The programs in the user memory together form a program block. The size of each program can be adapted as required, provided that the total quantity of programs fit into the user memory. The programmer has considerable freedom when designing a program structure - frequently repeated operations, variants of operations and fault routines, ete. are in separate programs. Program changes can be effected according to two different principles: Within the memory by calling up a program. Calling-up in its simplest form involves: 1. Interrupting the running of the current program; 2. Running a different program; 3. Resuming the running of the current program. A program which has been called up can in turn call up a third program, ete. up to 10 sub-levels ‘The built-in floppy disk unit offers two possibilities: - Replacement of the whole program block. All programs in the primary memory are replaced by a new block of programs downloaded from the floppy disk. After downloading a new program block, the newly loaded block of programs starts running with program 0. - Erasure of some programs and addition of a (short) program block. A desired number of programs in the primary memory are replaced by a down-loaded block of programs. After downloading a new program block, the current program block continues running in the primary memory. Some of the old Programs are retained. TRB 6000 154.3.2 | Movements ‘The operator programs a pattern of movements as a number of subsidiary movements between required positions (point-to-point programming). Each Position is programmed by the operator moving the robot to the desired position ‘manually. A specific point, known as the work point or the Tool Centre Point (TCP) moves relative to the robot in a well defined manner. The TCP can be defined in any selected position and the system can store a number of different ‘TOPs in its memory. ‘The operator performs manual operation by using a joystick with three degrees of freedom. The speed depends on the joystick deflection. ‘The joystick interacts with a safety pad. The safety pad blocks all robot movement when in the released position. Manual operation During manual operation the robot axes are able to move in the following coordinate systems: * Rectangular base-oriented coordinate system (fixed coordinate system) * Axis-oriented robot coordinate system (fixed coordinate system) fro * Rectangular wrist-oriented coordinate system (moving coordinate system) Rectangular tool-oriented coordinate system (moving coordinate system) “Fg Description TRB 6000 16A Tool Centre Line (TCL) can be created by defining a base point (BASEP) together with the TCP in the wrist-oriented coordinate system. The TCL then constitutes the x-axis in a tool-oriented coordinate system. The TCL is mainly based on the orientation of a tool or a gripper relative to the turn plate and enables a gripper or a tool to be moved parallel to its own configuration. ‘* Fixed TCP (see Programming manual S3 art. no. 3HAB 0002-2 ). ‘The function makes the manual operation of the robot, when the robot holds the workpiece and the tool is fixed mounted in the room. At reorientation of the workpiece the movement is done in relation to the fixed TCP-point, un- depended of the position of the robot. ‘Automatic operation When the system is operating automatically, the robot will move from its current Position to a programmed position. Each position is stored in the memory as the position of the TCP together with either: the wrist orientation (wrist-oriented coordinate system) or, ‘* the tool orientation (tool-oriented coordinate system). ‘Three different types of automatic running are available: * Robot coordinate movement. All axes are individually moved at constant speed towards the programmed Position. All axes reach their respective end position simultaneously. * Straight-line movement, ‘The TCP/ICL is moved straight and at constant speed towards a programmed position. Any reorientation of the wrist or the TCL will be performed continuously during the movement, * Modified straight-line movement. Straight-line movement of TCP but "Robot coordinate” movement of wrist axes. ‘The system speed is determined by: an absolute speed in mm/s or inches/s for the current section of the program; ‘@ percentage of the absolute speed for each movement instruction; an adjustment factor as a percentage of the speed determined by the above Points. 4.3.3 Programmable functions Position programming instructions * General instructions: - Position; - Position accuracy; ~ Speed, as a percentage of defined absolute speed. * Supplementary instructions: - Aposition brought: ~ directly from a position register; = _ indirectly from a position register via an addr - Position offset value: + stored directly in an instruction; + brought from a numerical register. s in 2 numerical register. Description ‘TRB 6000 17- Duration, speed replaced by movement time; + Circular movement. - Continuous rotating external axis. Auxiliary instruetio: (validity within definable program sections) > Choice - coordinate system; - TCP values; ~ absolute speed. + Displacement: ~ translation of a movement pattern by a reference point; - translation and rotation of a program by a reference frame; Programmable load and wrist performance ‘The load of the robot ean be chosen and altered manually or directly in the ‘robot program, in the same way as TCP. This means that the robot performance can be optimal even when a large number of different weights are handled in the same program. Programmable wrist acceleration ‘Wrist acceleration for handling press tending applications and at low pay loads. Glue and Air flow Glue and Air flow reference signals are put out on two analog outputs at the ‘same time as the robot is positioned. Due to the lag in the robot movernnt and the delay in the gluing equipment, there is also a delay function which enables compensation during execution. Furthermore, it is possible to choose wheter or not the Glue or Air Flow should be proportional to the TCP velocity. Palletizing function ‘The positions of all parts on a pallet can quickly be defined by feeding in the positions of the parts at three corner points and the number of columns and lines. The plane can have any slope. Relative tool displacement Execution of movement or rotation in tool-oriented coordinates. ‘The arguments are set during programming or brought up from a numerical register during programmed running. SWI SWI (Spot Welding Interface) is a soft ware function for control of an external welding timer. The SWL-instruction contains weld program number and if required, a register for the opening time of the gun. It is not necessary to have special subprograms, which makes it very easy to program the robot and optimise the program. Further information is given in chapter 12 in the "Programming Manual $3”, art.no. 3HAB 0002-2. Adaptive control. ‘The robot system can be controlled by sensors mounted on the robot or on the object. The robot system can store signal data for a maximum of 16 sensors, and a maximum of 3 of the 16 sensors can be used during programmed running of an instruction. The robot system can receive the following types of signals from the sensors: + Digital 24 V signals at ordinary digital inputs; + Three digital + 24 V signals at the safety board; + An analogue signal of 0 -+ 10 V at an analogue input; (Requires at least one optional analogue board) Description TRB 6000 18A ‘The adaptive functions must be supplemented by sensors. ‘The various programmable functions are: + Search ‘The robot will search for an object as it moves towards a programmed position. ‘The search is successful when one of the sensors has found the object. ‘The result of a search can be used as: * a parameter for conditional jumps in the program. * reference for program displacement. + Speed control A sensor controls the speed during movement towards a programmed position. + Contour following Sensor signals control the course of the robot during movement towards a programmed position. Continuous rotating axis One external axis can be runned with constant speed independant of robot movements. Soft servo A function giving the robot a compliance individually controllable for each axis. The force towards the programmed position is proportional to the deviation. Soft servo is defined individually for each axis. To obtain a “softness” in a certain direction (e.g. the Z- direction), the position of the robot arm must be such that the movemnt direction of the axis concerned coincides with the direction of the softness. See figure below. Figure. The direction of the “softness” of axis 3 at different robot arm positions. Control and logical functions In-pos check ‘Used together with soft servo. A conditional jump may be performed as a result of a permitted deviation from the programmed position. Program handling: Call for subprograms: = direct call; = indirect call via numerical registers. + Return - Program loading from floppy disk: = replacement of complete program block; = _addition/replacement of program sections. - Request for superior computer control. Description TRB 6000 19Program execution: = Pause in program running, defined by: = time; = input conditions. + dump in a program: = uncondition: + conditional; = _ search stop condition. = Program stop. VO handling (option): Setting of digital outputs; ~ Reading of digital inputs; - Enabling/disabling of direct acting inputs (system /0); - Transmission of numerical values between /O and numerical registers. Register handling: = Storage in numerical registers of: = numerical values; - positioning offset values; ~ = current location (x,y,z values). - Processing of values stored in numerical registers by use of the four rules of ‘ithmetic + Storage of TCP location and wrist orientation. Other instructio: + Comments: - explaining program codes; - displaying execution status on the monitor (option); + __ explaining program stops. + Gripper control. 434 Editing functions Changing of: + Instruction = Position: - by running the robot; - by entering the value. - external axes - Arguments in positioning instruction. Searching for program or instruction by: Entering number; + Indexing forwards or backwards within the program; - Listing of program numbers used; + Listing of call-up sequence to the program active. Insertion of new instructions. Re-numbering of instruction numbers in even tens. Erasing of: + Programs; + Instructions, Copying of: - Programs; - Instructions. ‘Mirroring of a program. Description TRB 6000 204.3.5 Manually controlled functions Functions during programmed running Running: - Continuously forwards in the program; ~ In steps forwards in the program; = _ In steps backwards in the program. Manual restart after voltage failure. Simulation of - ‘All conditions satisfied’ - to end a pause in running the program; -_ ‘All conditions satisfied’ - for jumping within the program. Change of position for movement instruction. Manual operation of the system Clearing of program blocks so that: = The first instruction in program 0 is displayed; + All registers and outputs are cleared. Program displacement in three dimensions with reference frame Use of floppy dis! = Transfer of an entire program block within the memory; - Addition of an entire program block to the program blocks in the memory; + Addition of a single program to the program blocks in the memory; - Storage of an entire program block; + Initiating of floppy disk - erasing of an old floppy disk; - Loading and storing of back-up stored system parameters. - Erasing of block on floppy disk ‘Superior computer control (option): = Selection of running mode in relation to a superior computer (control from ‘computer or robot system); = Storing of a program block in the computer; Storing of a single program in the computer; ‘Loading of a program block from the computer; ‘Loading of a single program from the computer; Storing of back-up stored system parameters in the computer; Loading of back-up stored system parameters from the computer. Handling of: + Digital inputs. Checking of status; ~ Digital outputs. Checking of status - with possibility of changing status; + Numerical register. Checking of value - with possibility of changing value. ‘TCP handling: - Change or definition of the wrist- or tool-oriented coordinates for the TOP; + Direct-acting definition of the TCP; - Erasure of TOP. Alignment of the tool: - With one of the rectangular base coordinate axes; = With a previously stored orientation. Use of system data (system parameters) - Cheek on or change of a separate parameter value; - Loading of predefined parameter values; - Loading and storing of back-up stored parameter values, Choice of language for information displayed on the programming unit panel. Description TRB 6000 21* Listing of (option): + Messages from the fault buffer; + Single programs. - System parameters ‘* Listing of errors in plain language: - On programming unit = Monitor (option) - Printer ‘* system for off-line programming (option): - Definition of positions; - Storage of positions in a superior computer. ‘System parameters System parameters are a collection of data which allow the user to extensively adapt the robot system characteristics. Diskette included in delivery. To prevent loss of data, the parameters can be stored as back-up copies: on floppy disk; ‘* ina superior computer (option). ‘The robot system also contains a default set of the system parameters, stored in PROM. These parameters allow the system to be operative before the installation adaption commences. Anumber of the characteristics, definable in the system parameters, are: ‘* Movement optimizing ‘* AC drive units (robot axes and integrated axis = resolver offset in the calibration position; ‘© Robot axes: - working range. * External axis. ‘* Metric units or inches. ‘+ VO board organization. (System 1/0, SWI, Remote control, Grippers ete.) ‘+ Automatic restart. '* Connection of: - superior computer; + printer (option); + monitor (option). ‘+ Adaption of robot performance to different loads. Description ‘TRB 60005 TECHNICAL SPECIFICATION IRB 6000/ 2.4-120, 2.4-150, 2.8-100, 2.8PT, 2.25PE-75, 3.0-75 and $3.0-100 5.1 Features 5.11 Performance ‘Type of movement Working range Axis 1 (C) Rotation movement + 180° — - 180° (4179.9°) ‘Axis 2 (B) Arm movement + 10 -- 70° +140? - +10° (S 3.0-100) ‘Axis 3 (A) Arm movement + 105° - - 28° + 155° - +52° (S 3.0-100) ‘Axis 4 (D) Wrist movement + 300° ~ - 300° +200° - -200° (2.25 PE-75) Axis 5 (E) Bend movement ‘Axis 6 (P) Turn movement, Max speed (° /sec) 24-120 24-150 2.8-100 8.0-75 $3.0-100 2.25 PE-75 28PT Axis 1(C) Rotation 100 70 100» 100 10070 ‘Axis 2 (B) Arm movement 100 10 100 = 100/100) 70) ‘Axis 3 (A) Arm movement 100 70 100 = 100 10070 Axis 4 (D) Wrist movement, 210 110-2102 210210210 Axis 5 (E) Bend movement 150 110-150 150150150 Axis 6 (P) Turn movement 210 110-2102 210210210 ‘Handling capacity 24-120 24-150 28-100 3.0-75 S3.0-100 2.25 PE-75 See 5.1.6,Load diagram ‘Maximum load 120kg —:150kg 100kg = 7Hkg 100kg 75kg Max. moment of inertia See 5.1.6 Load diagram Extra load on upper arm See 5.1.7, Extra load Handling capacity for 2.8 PT See 5.1.8, Handling capacity Process force for 2.25 PE-75 See 5.1.10, Process forces .... Position resolution 0.25 mm Accuracy (at mounting flange, ace. to ISO 9283) Repetition accuracy (under constant operational <40.4 mm (24-120, 2.25 PE-75) conditions and thermal stability) <.0.5 mm (others) ‘Transfertime (point to point time) typical 24-120 24-150 28100 $8.0-100 2.25 PE-75 50 mm (2") 3000 max, 1500 ‘min, 50 000 hours Expected battery life-time 5 years Battery type 3.6 V Lithium Diskette capacity 7x32 kword (448 kbyte) ‘TCP positions ‘Number of: ordinary 0-19 fixed TCP 20-29 Definition range (from mounting flange) 2.4-120 2500 mm 24-150 2500 mm 28-100 2500 mm 2.8PT 2500 mm 3.0-75 2500 mm_ $3,0-100 2500 mm. 2.25 PE-75 2500 mm_ Room fixed TCP 24-120 +8000 mm +8000 mm +8000 mm +8000 mm +8000 mm £8000 mm Load datas o-19 Position registers Number of: 200 (No. 0-199) ‘Numerical registers ‘Number of: 120 (Nos. 0-119) Permissible values 0-432 767 (16 bits) 5.12.1 Battery for serial measurement board(on manipulator) Back-up capacity aprox. 1000 hours (4Ah) Expected life-time 3 years (< 50°C) Re-charging time 18 hours Description TRB 60000- 96 inputs / 0 - 96 outputs 0-4 inputs /0- 4 outputs Customer connections (on robot arm) R3.CP Power Grounding B3.cS Signals Screen Air R-12" (inner diam. 11 mm) Others 10 250 VAC/2 A 1 1 23 50 VDC/250 mA 1 1 ‘Max. 10 bar ty \airRi2" 5.1.4 Man- machine communication Programming method Number of menus Aids for dialogue ‘Messages from the system Choice of language for messages Display in programming unit Point to point method by: * interactive dialogue * manual running by Joystick. + offline via terminal 6 standard menus Plain language English, + 9 selectable Alphanumeric, 2 rows Number of characters per row 40 Aids for data entry ‘Numerical key pad + 5 multi-function keys Description TRB 6000 255.1.5 Working range 24-120, 2.4-150 2.8-100, 2.8 PT , 3.0-75. Angle 2, 93 (*) axis 2 (92) Angle 2/3 (92/3) Min, 25 * Max. 155° 90 * at synch pos 0 pos ° 1488 2075 1992.5 | 2075 2094 2075 1 338 2034 695 2224 873 2318 2 s7t 1583 974 1598 1475 1615 3 680 314 575 77 523 an 4 962 89 857 479 805 $74 5 2395 1336 2798 +1300 2999 1283 6 1802 2067 2159 2857 2337 2752 Description TRB 6000 26Working range 2.25 PE-75 Angl e @2, 93 (°) Angle 2/3 (92/3) POS laxis 2 (92)| axis 3 (¢3)]_ |Min. 25 ° Max. 155° o 0 0 90 ° at synch pos 0 1 -70 | -28 2 70 | 5 Position axis 5 centre (mm) 3 40 105 ws} CPE eee oe 0 | 1338] 2075 a oF oe 1 205 | 1963 = 2 421 | 1549 3 | 718 | 459 4 | 1000] 56 5 | 2246] 1349) 6 | 1669] 2397' Description ‘TRB 6000 27Working range S3.0-100 (shelf mounted) Angle 2/3 (92/3) point] _ 9 ki 93 Min 25°, Max 155° degrees|degrees | | 90° at synch pos 0 0 | 60 60 1] 10 | 52 Pe 2| 10 | 75 Position axis 5 centre (mm) 3] 90 | 155 i oo point] X (mm)|Z (mm 5 | 140 | 75 0 | 2704 | -142 6 | 117 | 52 1 | 2225 | 478 2 | 1657 | 94 3 | 334 | -177 4|-5 | -905 5 | 2103 | -1569 6 | 2907 | -889 Description TRB 6000Xm) 30 07 45 kg C3 Valid for» Jo < 10 kgm 60 ke i Tks IK o4 100 kg) | 03 L220 ke 02 01 \ > O1 02 03 04 05 06 07 Ym iC Tq : ee Ye Load diagram for 15> J,>1 0 kgnf m*K,? +5.6*m*X, +288* X,+m +744 * Jy = 4644 Yq = ((9.06- 0.24% Jg)/m) 07 Xp=Xq-0.142*Yp Yo = Yg+ 0.484 *Xp ‘Jo = own moment of inertia, of the total handling weight, in it’s centre of gravity kgm?) tal handling weight (kg) X, Y= see figure above Description TRB 6000Load diagram 2.8-100 '$3.0-100 8.0-75, 2.25 PE-75 (Max handling capacity limited to 75 kg. The curve for 100 kg is not valid.) Xm 0,7 ee pe 0,6] — P45 05 60lkg Valid for, 4 J <10kgm 15 03 F100 ke 0,2 01 O1 02 03 04 05 0,6 Yc) x, h Soh u Yo Y Load diagram for 15> Jj>10kgm? m*X,?45.6 * m*X,+ 240 *X,+m+6.2*Jy= 387 ‘Yp = ((7.55 - 0.2 * JgVm) 07 Xp =X, - 0.142 *¥p Yo=Yp + 0.484 *K, Jo = own moment of inertia, of the total handling weight (kgm?) 1m = total handling weight (kg) X, Y= see figure above Description IRB 6000‘Load diagram 24-150 X@) Valid for 2 Jy 10 kgm > 05° 06 © ¥(m) Xs Ye Load diagram for 15> J,>10 ken? m *X,2- 0.89 * m*X, +250 *X, + m+ 0.62 * Jy = 220 Yq = (11.5 - 0.32 * JV m)° Xp=X,-0.118* Yp Y= ¥p + 0.346 *X, wn moment of inertia, of the total handling weight (kgm?) tal handling weight (ke) X, Y= see figure above Description ‘IRB 6000 315.17 Extra load Upper arm _ Extra load is permitted to be mounted on upper arm. Definition of distances, masses are shown in the picture below. When programming the robot, the total extra load on upper arm must be stated to its size and position. See Installation Manual S3/ system parameters for software limitations. 2.4-120, 2.4-150, 2.8-100, 2.8 PT, 2.25 PE-’ Balancing axis 2 Standard (Type A) Permitted extra load on upper arm plus the max handling weight. Mis 35 kg with a < 500 mm, centre of gravity in axis 3 extension 5 or M2s35kg = b= 400mm or M3<10kg — ¢< 300 mm (If there is a lower handling weight compared to the max weight, M1 alt. M2 can be increased according to: Mi(alt. M2) + handling weight < 35 + max handling weight Ref. to 5.1.1 Ex. M2 can be 75 kg if there is only 80 kg as the handling weight for 2.4-120.) 3.0-75 Balancing axis 2 Standard (Type A) Permitted extra load on upper arm. Mis 35 kg with a < 500 mm, centre of gravity in axis 3 extension or Mas 20kg b<400mm or M3s5kg ¢< 300mm $ 8.0-100 Balancing axis 2 Standard (Type C) Permitted extra load on upper arm. M1< 35 kg with a < 500 mm, centre of gravity in axis 3 extension Mas 35kg b<400mm. or M3<10kg ¢< 300mm (if there is a lower handling weight compared to the max weight, M1 alt, M2 can be inereased according to: Mi(alt. M2) + handling weight < 35 + max handling weight Description TRB 6000 828 3.0-100 Permitted extra load on frame. Position according to figure. ‘Mas 200 kg with d< 220mm | M4200 kg, VLILLILILL D WT) 240, Description View TRB 6000Handling capacity at presstending valid for 2.8 PT ‘The weight and the dimension of the part and the gripper are limited by maximum allowed static torque and moment of inertia. ‘Static torque, M: A-movement: Axis 5 Ma, < 650Nm B-movement: Axis 4 Mb, < 650 Nm d= 8 ANAANTSNSSTS Movement mainly Asmovement ‘with axis 1 and 6 (inward movement) fo se Eee Moveaeot maaly eee whose a dard, Moment of inertia. J; Acmovement: Axis 5, Jag< 105 kgm? Axis 6, Jag < 120 kgm? Bemovement: Axis 4, Jb, < 105 kgm? ‘Axis 5, Jb, < 120 kgm? roxim: low: .81 * (m, *r +m, *s) Wm) = 9.81 * (m,* (r+ 0.2) +m, *(5 + 0.2)) Wm) Jag = m,/12* 2 +m, * 12+ m,/12* a +m, +s? (kgm?) Jag = m,/12* o? +m, * 1? +m,/12* (a? +b?) +m, +? (kgm?) 1/12 * chm, * (r+ 0.2 +m,/12* a+ m,* (s +02)" (kgm?) Tb, = mz/ 12 * 0? + me * (r+ 0.2 + m,/ 12* (a? +b?) +m, *(s+0.2)" (kgm?) m,= weight of gripper (kg), m, = weight of part (kg) Distance a, b, ¢, r and s(m) are shown in the figures below. Deseription TRE 6000A-movement, gripper perpendicular to axis 6 B-movement, gripper parallel to axis 6 Description TRB 60005.1.9 Cycle time at presstending for 2.8 PT A rough estimation of the cycle times (press stroke) are shown in the diagrams below. This diagrams are valid for grippers with vacuum cups and short positioning time for the gripper (pick up/leave time app. 0.3/ 0.3 s). If the gripper is not working with vacuum cups and/or the space between the moulds is short, the cycle time will increase due to long pick up/leave and positioning time. Asmovement, inward: (Handling the load inside the centre of axis 6, during the cycle) Ja,= 100 kgni g CYCLE TIMES [sec] Ja = 20 kent’ 3 aa 4 5 6 7 8 9 PRESS DISTANCE [ m ] Description TRB 6000 36A-movement, outward: (Handling the load outside the centre of axis 6, during the cycle) Jag= 100 kgm 7 CYCLE TIME= (sec) _ — = Jae= 20 kgm * 9 sb vom | | Lem 8 di a 7 a A 7 - = 6 a 5 4 3 — 4 5 6 7 8 9 PRESS DISTANCE [m] B-movement: —————_ Jb,= 100 kgm 7 CYCLE TIME (sec) 2 — — — Jb,=30kgm 9 | ——] on ae == ; L-- 6. 5. 4. + 4 5 6 7 a 9 PRESS DISTANCE [m] Description IRB 6000 375.1.10 Processforces for 2.25 PE-75 Max force + force through the wrist centre © 0-65° rel. the vertical line -> 5000 N * 65-90° rel. the vertical line -> 4500 N + 90-115° rel. the vertical line -> 3500 N Offset from the wrist centre ‘Max offset force is 3500 N when r = 100 mm. the direction must be parallel to the x-axis, according to chapter 5.1.6. ‘Time at max force < 1 second exclusive reweld <3 seconds at reweld Description ERB 6000Rise time: Due to the dynamic forces and the backward elastic deflection in the robot the rise time for the rebuilding of the forces in the air cylinder must follow the values below. ‘Min time to achieve 90% of max force: F>3500N — >0.15 sec. F<3500N > 0.03 sec. Min. time to go from 100% load to 0% load: F>3500N > 0.1sec. F<3500N > 0.03 sec. Angular fault from x-axis, see chapter 5.1.6, must be < 5°, ‘The distance between the weld cylinder and the weld plate: 15 mm. ‘The number of permitted poke points per minutes: Force contact surface 1 sec. (Valid cabinet temp. 45°C. Number of points can be increased if cabinet temp. can be decreased. Cabinet temp. can however not be increased lower than environment temp. Axis ‘%Moment* Number of points? 1 100 35 5 68 50 15-20 2and3 100 12-25 5 26-40 1) 100% = maximum torque load on present axis. 2) The lover value is valid when present robot axis, carry out large movements. ‘The higher value is valid for small movements of the present axis. Description TRB 6000 395.2. Requirements 5.2.1 Environmental requirements Protection standard Manipulator IP 54(NEMA 12) Wrist IP 55 Control system IP 54(NEMA 12) Explosive atmosphere ‘The robot shall not be placed and operated within explosive atmospheres Ambient temperature Manipulator +5°C(41°F) — + 50° (22°F) Control system and prog. unit (incl. heat exchanger) +5° (41°F) — + 40° C(104°F) (with air conditioner) +5°C(41°F) — + 45° C(113°F) During transport and storage, complete system = 25° C(13°F) — + 55° C(131°F) Relative humidity ‘Complete system during transport and storage ‘Max. 95% at constant ‘temperature 5.2.2 Electrical connections Power supply Mains voltage, 16 A, three-phase 200, 230, 400, 440, 475, 500, 525, 600 V Voltage tolerance + 12% - -15% WO (option) can also be supplied from external voltage supplies for galvanic isolation. See chapter 6, Control system (Input/output capacity). Frequency 50/60 Hz ‘Frequency tolerance +1Hz Power consumption ‘MOTOR ON, program running 45 kW ‘MOTOR OFF O5kW 5.3 Physical data, dimensional drawings 5.3.1 Physical data Weight Manipulator 2.25 PE-75 +1575 kg (3465 Ib) 24-120 1825 kg (4015 Ib) 24-150, 2.8-100, 2.8 PT, 3.0-75, 1950 kg (4290 Ib) $3.0-100(shelf mounted) 2450 kg (5390 Ib) Control cabinet system 280 kg (616 Ib) ‘Volume Manipulator excl. packing see next page Control system 2065 x 915x 530 mm ( 81" x 36" x21") Airborne noise level ‘The sound pressure level outside the safe guarded working area $70 dB (Leq) Deseription TRB 60005.32 Dimensional drawings Manipulator 2.4-150, 2.4-120 (The measurement R 762 is valid for 2.8-100, 3.0-75 and 2.4-150) Description IRB 6000 aDescription TRB 6000200 704d 950 834 8 > r M 12426 (x4) ‘TRB 6000 Descriptionc-c 193, M10 xd MB (2x) cc 112 Description TRB 6000‘Support surface LE [0-88 (x3) Description ‘TRB 6000Control system Space required nee 100800 | If the free space (gray zone) around the cabinet is less than 100 mm, a heat exchanger or air conditioner is necessary. View from above Cooling device Front view Pockets for forklift Description TRB 60005.4 Standards 5.4.1 General ‘The mechanical robot and the control cabinet have been designed to fulfil the requirements in TEC 204-1 and SS EN 60204. ‘The SS EN 60204 document contains the text from IEC 204-1, but with a number of ‘modifications and supplements common to CENELEC (Comité Européen de Normalisation Electrotechnique). EN 60204 is common to all EEC- and EFTA- countries. 5.42 Safety ‘The robot is designed in accordance with the requirements of ISO 10218, Jan 1992, Industrial Robots Safety. The robot also fulfils the requirements in the Manchinery Directive 89/392/EEC as defined in EN 775, October 1992. The robot also fullfll the ANSIRIA 15.06-1992. With the exeption of slow speed definition. 5.4.3 Electromagnetic Compatibility. ‘The robot consists of a manipulator IRB 6000, Control system S3 and control cables fullfill necessity demands in EG:s EMC-directive (88/336/EEC): - Fullfill the demand in CISRP 11 (radio frequene emmisson in the range 30 - 1000 MHz. Conducted interferenses voltages in frequency range 0,15 - 30 MHz. = Pullfill EC 801-3 that means radio frequency immunity (10 Vim in frequency range 26 - 100 MHZ). Description TRB 6000 4aDescription TRB 6000a BS BRRREBE Y 651 652 Robot specification ‘The options for the IRB 6000 are described below, using the same number references in this document as in the order on the specification form. Robot version IRB 6000/2.4-120 required opti IRB 6000 / 2.4-150 required opti IRB 6000 / 2.8-100 required option: IRB 6000/2.8 PT required option: 444 IRB 6000 / 3.0-75 required option: 443 IRB 6000 / $3.0-100 required options: 443, 43 IRB 6000/ 2.25 PE-75 required options: 444, 43 Application interface (CUSTOMER CONNECTION) Air and signals to upper arm ‘An integrated air supply system is located within the upper arm. Connection in the base and outlet in the moving section of the upper arm. Connection: R1/2" in the upper arm and R1/2” in the base. ‘The signal system is part of the cabling of the robot. Connection point at the turning point of the upper arm, consisting of two contacts. See section 5.1.3 Signal Capacity and Installation Manual, chapter 7, Customer connections. 3.0 -100 and 2.25 PE-75 version supplied as standard with air and signals to the upper arm, Connection of signal system to manipulator base Direct signal connection on the contaets R1.CP and R1.CS. Cabling not included. Connection of signal system to controller Cables for connection also contact R1.CP and R1.CS supplied. The following lengths for manipulator to control cabinet are available: Im 15m Fig.6.1 Connection of signal system to manipulator base Description TRB 600060 Lifting device for fork-lift truck ‘The manipulator is equipped with a lifting device to hoist the manipulator using a fork- Tift truck. 61 For 2.4-120, 2.4-150, 2.8 PT, 3.0-75 and 2.25 PE-75. A standard lifting device only for overhead crane lifts is not included. ee For $3.0-100. Hoisting eye bolts for overhead erane included 120 Connection of control cable 121 Cable connection on left side ee Cable connection on roof ‘Motor cable Measurement cable Fig 62 Cable connection on roof 180 Connection of mains supply ‘The way the main voltage is connected to the control system can be selected from either permanent installation or with wall terminals on the left side of the cabinet. 131 Cable bushing Connection is at the mains filter in the control cabinet, the cable being led through a serew cap in the wall 11-12 mm. diameter. Connection via wall terminal as per IEC 309-1, -2, CEE 17. Fig63 Wall inlet. Description TRE 6000132 133 134 140 41 143 145 3x 16 A with protective earth. 3x32 A with protective earth. Industrial contact unit as per DIN 41640 35 A 600V, 3 phases + earth protection. ‘Neutral can also be connected to this terminal Fig 6.5 Contact unit Mains supply circuit-breaker Rotary switch as per IEC 204, IEC 337-1, VDE 0113. UL, EN 60204. ‘As an accessory for the rotary switch there is a 20 A circuit breaker, for protection of the main voltage in the eabinet. According to IEC 898, VDE 0660. Fig 65 Circuit breaker Flange disconnect switch The control system can be provided with a front-operated flange disconnect switch ‘mounted on the rear wall of the control cabinet, maximum voltage 480 V, with integral 20 A circuit breaker. The flange disconnect switch is in addition provided with mechanical door interlocking when the switch is in the ON position. For service purposes door interlocking can be by-passed using a screwdriver. Description IRB 6000 51150 151 159 181 182 Mains voltage ‘The robot can be connected to mains voltages between 200 V - 600 V, 3 phase + protective earth. ‘Transformer 1 Transformer 2 . 200 V . 380/400 V . 220/230 V- . 400/415 V_ . 500 V . 440V . 525 VV . 475 V. . 600 V_ Placing of operator panel The units for operator communication are an operating panel and a programming unit. The operating panel, the shelf for the programming unit and the monitor (opt 403) can be located either: + At the front of the control cabinet * Ina separate unit for operator communication, cable length included 15 m. Control electronics for external axes Apart from the six axes of the manipulator, the system can position-control one external axis. The control cabinet contains parts of the electronics necessary to control the external axis. Connection is cabinet. ia contact devices complying with DIN 43652 on the left side of the The following programmable functions also apply tothe external axis: Running up to a progam position, including the percentage speed value, with or without stated positional accuracy. . Parallel displacement of the motion pattern with the help of a reference point. ‘The result will be a displacement of the pattern along the work envelope for the axis in question (linear movement), or movement of the motion pattern around the rotation centre (rotating movement). ‘The control cabinet can be equipped as in one of the following alternatives: 191 Drive unit for axis 7 of the same type as the manipulator axis 1-3. Intended for track motion IRBT 6000. 198 Signal adaptation for control of 1 external axis. Drive unit is not included. Description TRB 6000 52MOTORS ON 1 DRIVE POWER Fig. 6.6 Signal adaptation for external axes with external drive units Signals to external drive system: MOTOR ON (double contacts) BRAKE, Speed reference Motor speed Signals from external drive system: POWER OK ‘Synchronising switch Feedback Resolver specification: Excitation: Rated data 250 V AC/110 V DC, 1A Rated data 250 V AC/110 V DC, 1A. +10V analogue max. 3000 rev/min 24V DC from control system 24 V DC or resolver supply Ist resolver ratio 1:1 2nd resolver ratio 136:137 Resolver of transmitter type Voltage ratio 2:1 (rotor:stator) ‘To one or two resolvers and to synchronising switch. Excitation voltage 5.7 V/2 kHz ‘When track motion IRBT 6000 S is used, option 191 is to be chosen. TRB 6000200 VO CAPACITY ‘VO units are not included in the basic versions of IRB 6000. Inall, there are 6 available 1/O slots (max. 5 with option 405 Winchester memory included): . digital VO, 16 in/16 out, max. 6 units (1 slot per unit) . analogue V/O, 4 in/4 out, max. 1 unit (1 slot) : AD combined V/O, digital 16 in/ 16 out and analogue 2 out, max. 1 unit (1 slot) . RIO remote link for Allen Bradley PLC, max. 1 unit (2 slots) With regard to analogue and combined V/O, only one of the units can be used in the system at the same time. 20x Digital inputs and outputs (0) Digital VO unit Inputs: 16 opto-connected ‘Nominal voltage: 24 VDC Current at nominal input voltage: 5.5 mA Outputs: 16 opto-connected, short-circuit protected Nominal output voltage: 24 V DC Load capacity per output: 200 mA Maximum load per group of 8 outputs: 1A ‘The unit is divided into 4 grou ‘ith 8 inputs or outputs in each. Each group requires a separate voltage supply according to one of the following: . Internal supply from the control system, not galvanically insulated from the electronics in the cabinet, . External supply, galvanically insulated from the electronics in the cabinet. Voltage range 19-35 VDC. Connection points for internal and external supply are provided in the system. Reserved V/O groups Four groups of digital 1/O can be reserved via the system parameters: +" system VO + remote control panel + gripper 3-8 + digital glueing VO . SWI ‘The contents and significance of reservations are described below: System /O Contents: Control signals for: * operation of grippers 1 and 2 (outputs) Interrupt signals (inputs): + CALL for sub program 1-5 (inputs) + INTERRUPT PROGRAM + __ INTERRUPT INSTRUCTION Status signals (outputs) for: + MOTOR ON Description TRB 6000CYCLE ON ERROR (error during program running both AUTO and MANUAL) Operating mode selector in position MANUAL SEARCH STOP Requires 8 inputs/8 outputs Location: Last half of chosen /O board. Activated system 1/O will shift subsequent numbering of inputs and outputs. ‘Not valid if the function /O-map have been used. Remote panel Contents: Inputs: MOTOR ON MOTOR OFF FROM DISKETTE KEY (locked programming unit) LAMP TEST PROGRAM STOP PROGRAM START SYNCHRONIZE (external axis) Outputs: MOTOR ON ‘MOTOR OFF PROGRAM STARTED PROGRAM STOPPED FROM DISKETTE ERROR (all errors, including handling errors) EMERGENCY STOP ‘SYNCHRONIZE (external axis) ‘Requires: 8 inputs/8 outputs Location: First half of chosen V/O board. Activated remote control panel will shift subsequent numbering of inputs and outputs Not valid if the function /O-map have been used... Gripper 3-8 Contents: 1.6 control signals for gripper operation. Requirement: 1.6 outputs depending on the number of grippers. Location: ‘Sequential placing according to output chosen for gripper 3. Digital glueing /O (GL) Contents: Glue blocking, glue reference error Reserved: 1 input/ 1 output Location: Input 6/output 7 SWI Spot Weld Interface (SW) Contents: Control signals for welding controller (outputs): . Start 1 . Start 2 . Current enable . Weld power . Reset : Gripper 1 . Gripper 2 . Parity * Weld program "1" Call weld prog. 9-13 * Weld program "2" Description TRB 6000. ‘Weld program "4" ‘Weld program "8" . ‘Weld program "16" Control signals from equipment and weld controller (inputs): Weld ready ‘Timer OK Current OK Flow OK ‘Temp OK Enable move Requirement: 6 inputs/13 outputs Location: First half of the inputs and both halves of the outputs on the /O. board selected. VO map ‘The system is supplied as standard with the above configuration. By using an /O map inputs and outputs can be individually allocated an optional channel (‘mapping’) to adapt 1/0 to the installation, For further information regarding V/O mapping, see the installation manual for $3. VO ports Series and parallel /O are available and can be activated from the user program when necessary. ‘When they are not activated as ports, they operate as individual inputs and outputs. Series ports Input port Design: 4 parallel input channels for 16-bit data words, 4 outputs for control data 2 out + 1 in for hand-shake routines. Requirement: 6 outputs/5 inputs Location: Output 1-6 and input 15 Output port, Design: 4 parallel output channels for 16-bit data words 2out + 1 in for hand-shake routines. Requirement: 6 outputs/1 input Location: Output 1-6 and input 5 Parallel VO ports Abit VO ports Quantity: in and 2 out. i Input/output 1-4 and 13-16. 2in and 2out Input/output 17-24 and 25-32 Description IRB 6000227 Analogue VO unit (with common 0-V) Inputs: 2.with switching frequency Data: Input impedance Input voltage Resolution ‘Accuracy 3 voltage outputs Output voltage Load Resolution Accuracy 1 eurrent output Output current Load Resolution ‘Accuracy 2 with switching frequency = 10 Hz for the input filter (00 Hz for the input filter 1Mchm #10V 10 mV (10/1024 V) 15 mV + 0.2% of input voltage +10V >2kohm 10 mV (10/1024 V) 25 mV + 0.5% of output voltage 420 mA ‘<450 ohm 20 pA (20/1024 mA) G0A+ 0.5% of output current ‘The analogue unit requires separate power supply +15 V according to one of the following alternatives: . Internal +15 V supply, not galvanically insulated from the electronics in the control cabinet, only intended for analogue V/O. Internal supply is available in the unit's connector. + External supply, galvanically insulated from the electronics in the control cabinet. ‘Voltage tolerance ,+ 5 % Connection points for internal and external supply are available in the system. Reserved 1/0: Analogue 1/0 reserved for glueing (GL): Contents: - Glue flow reference - air flow reference Requirement: 2outputs Location: output CH 1 and CH 2 Description IRB 6000 387AD Combi 1/0 unit Digital inout Inputs: 16 opto-connected ‘Nominal input voltage: Av Input current at nominal input voltage: 5.5 mA Outputs: 16 opto-connected, short-circuit protected Nominal output voltage: wv Load per output: 200 mA Load per group of 8outputs: 1A ‘The unit is electrically divided into 4 groups with 8 inputs or outputs in each group. Bach group requires a separate voltage supply according to one of the following alternatives: . Internal supply, not galvanically insulated from the electronics in the control cabinet. . External supply, galvanically insulated from the electronies in the cabinet. Voltage range 19-35 V DC. Reserved V/O, see 20x Digital /O Analogue out Outputs: 2 voltage outputs Output voltage 0-+10V Load >2kohm Resolution 10 mY (10/1024 V) Accuracy 25 mV + 0.4% of output signal ‘The analogue unit requires separate voltage supply +15 V according to one of the following alternatives: . Internal +15 V supply, not galvanically insulated from the electronics in the control eabinet, only intended for analogue Y/O. Internal supply is available in the unit's connector. . External supply, galvanically insulated from the electronics in the cabinet. Voltage tolerance + 5%. Reserved VO, see 227 Analogue /O Description TRB 6000241 RIO board Allen Bradley ‘Remote link (remote I/O) for communication with Allen Bradley PLC. With the RIO function, up to 128 inputs and outputs, in groups of 82, /O, can be transferred serially to a PLC control system equipped with Allen Bradley 1771 RIO node adapter. Only digital, system, and remote panel signals can be transferred with RIO. Connection to RIO is via screw terminals on the inside rear wall of the cabinet. ‘The RIO board takes up two board slots in the rack. Number of digital VO boards ‘Number of YO via RIO ° 128 12 96 3-4 (max) 64 ‘Thin product incorporates commonicaton isk which ie cenaed under patent and propitay tachaclgy of Allen Brady Comgany, Ine. Alle Bradley Company, Ln. oe not warrant or support hie profuct Al warranty and eapport service fr {SS odbc are the reepnety o and proned by ABB Ratasce Prosoce 300 ‘TYPE OF CONNECTION ‘The control system connections can be adapted to various needs through choices shown below. 30x Freeend Customer connections are available on the inner rear inner wall of the control system. ‘Via an extended ribbon cable with 40-pole connectors for digital or analogue signals, these can be connected to a customer-specific relay and /O panel (not supplied), which is placed on the inner rear cabinet wall. Cable contacts are of type DIN 41651. Description TRB 6000Six External connection ‘The standard connections to the robot are with 64-pole plug-in connectors DIN 43652 on the outer left-hand side of the control system (seen from the front). Fig 6.7 External connection 33x Screw connection For customers who do not desire plug-in contacts there is the possibility of connecting signals (apart from the robot's control signals) to various types of screw terminals. These are mounted on the rear inner wall of the control system. ‘The screw terminal units are mounted on mounting plates provided with cable channels, and standard EN 50022 bars for attaching the serew terminal units. ‘The number of bars are matched to the options selected. In all, up to 5 bars can be mounted; however, this is reduced to 4 with opt 146, flange disconnet switch. Description TRB 6000Fig 6.8 Option mounting plate Safety signals Safety signals, ete., are connected on a unit (1) on the lower bar. If the option of customer connection (651-656) is selected, these terminals (2) are also placed on the bar furthest down. Analogue signals Analogue signals are connected on a screw terminal unit as fig. 6.8. This unit (3) is to be placed on the second bar to the left of the first digital screw terminal unit. Fig 68 Screw terminals unit 339 VO supply terminals (4) Provided with eight 2 A fuses for fuse protection of 24 V supply to /O, ete. ‘As standard, the fuses are connected to the control system's 24 V DC supply, and to all digital screw terminal units. Description TRB 6000 61Fig 6.9 /O supply distribution block with fuses. For V/O signals, one of the following board units is selected 34x ‘Screw connection. Digital /O (5). Up to 4 units, as fig. 6.8, are mounted on the same bar. 96X ‘Screw terminal connection with disconnect possibility for trouble shooting. Up to 3 placed on the same bar. Fig 6.11 Screw terminals unit with disconnect. DescriptionSix Relay units (6) ‘Terminal unit with 16 relay outputs. This option can be selected alone or in combination with 34x or 36x. If the relay units are combined with 34x or 36, they are placed after the other terminal units, In addition, the relay unit is equipped with 10 + 10 terminals for 24 V DC supply and 8 + 8 terminal for optional supply. Max. load per terminal group 6.3. A. Data relay unit outputs 16 relays with one change-over contact. ‘Maximum current 4A per relay Rated voltage 250 VAC Inputs according to option 20x. T he inputs are not seperated by relays, [SSS/SS5/ Ss Sea] seu] [seu] sou] sue sou [sos] Sse] sou] Sor poTSSTSSS ee TAT ATARI AID Fig 6.12 Relay units Connections from connectors 88x # External connections via screw terminal board All signals are connected to 64-pole contact units as per DIN 43652 with pin arrangement as per insulation manual $3. As in 38x above, but where the user establishes the pin arrangement by filling in the wiring table 3HAB 2123-7 in conjunction with his order. ADDITIONAL EQUIPMENT ‘The robot system can be supplied with any desired combination of additional ‘equipment as follows: Program print-out ‘The print-out function makes it possible to connect a printer to the robot system for printing: : Individual programs including TCP positions. The operator is able to request 5 print-outs through a signal command. : ‘The contents of the fault message buffer. : System parameters. Description TRB 6000‘The robot communicates with the printer through asynchronous series transmission via an RS 232 signal interface. This printer must be fitted with an internal buffer memory. ‘The connections for the printer are situated on the front of the control system, where there is a 25-pole contact (D sub). 402 Computer link ‘This function permits communication between the robot and a host computer. Communication takes place in asynchronous series form with an RS 232 signal interface. A programmable instruction is provided: During programmed running, control of the robot system is transferred to the host computer. It is possible to work as follows with the computer: - the computer controls the robot - the computer loads/stores program blocks or individual programs the computer changes the running status of the robot - the computer starts/stops programmed running of the robot 5 the computer erases individual programs - the robot transmits status information : the computer stores status information from the robot ‘At any time the operator can disconnect the computer control of the robot. An additional system parameter defines the identity of the robot (0-127) for the computer. The computer is connected to a 12-pole contact device on the outside of the left-hand wall of the control system. For further information, see Description Computer Link. 403 Monitor (LCD) The control system can be supplied with a monitor. All the electronics for the monitor is placed in the control cabinet. ‘The operator has access to the following functions from the monitor: Display of parts of the current program with the activated instruction marked. Activation of a new program or any new instruction is shown. . Valid program data are displayed above the actuated section of the program. Any changes in the program data will appear on the screen. . ‘The operator can ask for listing of the contens in the error message buffer: Should an error occur, the monitor will show error messages. During program execution, the monitor displays the comments included in the Programs, one ata time, as the program proceeds. Description TRB 6000420 421 BER 431 Winchester memory ‘The Winchester is a hard disk memory to store up to 250 program blocks. Its operation is the same as for floppy disks, but no robot parameters can be stored. ‘The time taken to read off a complete program from the Winchester is 6-7 seconds. ‘lumination in cabinet ‘The cabinet can be provided with internal illumination that lights up when the door is open. For method of power supply, see option 430. Service outlet For service purposes, an outlet (7) as per standard below can be selected. The outlet is located on the bar furthest down on the rear inner wall of the cabinet. The outlet is protected with a 2 A fuse. All are provided with protective earth connection. 230 V mains outlet as per DIN VDE 0620 (Germany, Sweden, ete.). 230 V according to French standard. 115 V according to British standard. 115 V according to American standard. Connections to service outlet and illumination. Power supply to service outlet and illumination can be of three different types. ‘The outlet may be loaded with up to 100 VA when the control cabinet door _is closed. Connection from main transformer. ‘The voltage is switched off with the mains switch on the front of the cabinet. ‘Serve outlet and Mluminaton options "200 600VAC uF 015 ¥ ptienal arch Pat Protection oe daada co ‘e Fig 6.14 Connections to service outlet and illumination 3. Description TRB 6000gs Connection in front of the mains switch without transformer. N.B. only for main voltage 380 V three-phase with (opt 153) neutral connection and service outlet for 230 V (opt 421, 422), Cannot be combined with CEE intake (opt 132, 133) since these intakes have no neutral connection. Connection in front of mains switch with transformer 380 V - 500 V (only together with opt 153 157) with secondary for 115 V and 230 V, 2 A. For both 432 and 433, the voltage is to be switched off with an circuit breaker mounted in the upper section of the left- hand wall of _ the cabinet. The cireuit-breaker is approved in compliance with IEC. Earth fault protection for service outlet (8) For better personal safety, the service outlet can be fitted with an earth fault protection that trips at 30 mA earth current. The earth protection is placed alongside the service outlet. Operating voltage 110 - 240 V AC COOLING EQUIPMENT ‘Heat exchanger For all versions, apart from 2.4 - 150, 2.8 PT and 2.25 PE-75, the control system is supplied with a permanently mounted heat exchanger placed on top of the control system. The heat exchanger is only in operation when the door of the control system is closed. Air conditioner The control system is supplied with a fixed air conditioning unit for 2.4 - 150, 2.8 PT and 2.25 PE-75. Other versions can also be supplied with a air conditioning unit. With the help of this equipment, the temperature in the cabinet can be kept at a constant level, set at 45° C even if the ambient temperature is raised to 45° ‘The air conditioning unit is only in operation when the control cabinet door is closed. Description