ABB FlexLoader, Applications Manual

Page 1: ...ROBOTICS Application manual FlexLoader Standard Safety Center ...

Page 2: ...Trace back information Workspace Robots and Applications version a61 Checked in 2020 03 06 Skribenta version 5 3 033 ...

Page 3: ...Application manual FlexLoader Standard Safety Center R19D Document ID 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained ...

Page 5: ...ntenance 31 5 Interface 31 5 1 External safety interface to connected system 38 5 2 Internal safety interface 43 6 Function description 45 7 Operation 45 7 1 Starting from a non powered status 46 7 2 Protective stop 49 8 Decommissioning 49 8 1 General 50 8 2 Environmental information 53 A Technical data 53 A 1 Introduction 54 A 2 Safety functions 57 A 3 Error messages 58 A 4 Starting from a non po...

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Page 7: ...nel repair personnel service personnel operators Prerequisites Operators and maintenance repair and installation personnel working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation service and maintenance work Trademarks FlexLoader is a trademark of ABB References The product manual of the robot used together with FlexLoader Standard...

Page 8: ...terlocking devices associated with guards Principles for design and selection EN 60204 1 Safety of machinery Electrical equipment of machines General requirements Newer applicable standards and regulations supersede the above standards Revisions Description Revision First edition A Updated illustrations B General update C Include Profinet update Improved information on master slave interfaces D Mi...

Page 9: ...led correctly Personnel working with the robot must be familiar with the operation and handling of the robot as described in the applicable documents Only personnel with required training are authorized to use the system All received training must be documented in writing System integ rator Qualified elec trician Trained service and maintenance techni cian Trainedoperat or Activity X Commissioning...

Page 10: ...ation before unpacking and installing the equipment Personnel who are involved in the installation and commissioning must have relevant training for the respective robot and corresponding safety issues 10 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 1 Safety 1 2 Safety during installation commissioning and decommissionin...

Page 11: ...regulations Work on electrical systems or operating material must only be carried out by a qualified electrician or by a trained person under guidance and supervision of a qualified electrician according to the applicable electrical technical regulations All safety and warning signs must be kept clean and legible If necessary replace them Always check the function of all safety devices after perfo...

Page 12: ...aused for any of the following reasons Use of FlexLoader Standard Safety Center in other ways than intended Incorrect operation or maintenance Operation of FlexLoader Standard Safety Center when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications made in ...

Page 13: ...ustrial Robots and Robot Systems Safety Requirements and UL 1740 Standard for Robots and Robotic Equipment In Canada refer e g to CAN CSA Z434 03 Industrial Robots and Robot Systems General Safety Requirements Note The supplied equipment must not be operated until the processing machine or system in which the equipment is included has been approved according to national and regional laws and regul...

Page 14: ...fe access to all areas where intervention is necessary during operation adjustment and maintenance Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations Safety zones which must be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turn tables or...

Page 15: ...s so that the system can be stopped quickly If any of the buttons do not stop all the robot workcell motion each emergency stop button must be marked if more than one is provided to indicate its designated safety function Changes to Pluto program Applicable for systems with the optional safety center WARNING The Pluto program is a critical part of the automation cell s safety system Apart from con...

Page 16: ...esult in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation which if not avoided...

Page 17: ... where to find additional information or how to do an operation in an easier way TIP Application manual FlexLoader Standard Safety Center 17 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 1 Safety 1 7 Safety signals in the manual Continued ...

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Page 19: ...ured and covers a broad range of safety interface needs DANGER The Pluto program is a critical part of the safety system of the cell No changes may be carried out without a qualified inspection and verification of the safety risks and the behavior of the safety system as a whole Area of use FlexLoader Standard Safety must only be used in cells with intended safety classification and on the conditi...

Page 20: ...fety chain single chain A Internal emergency stop chain B Dynamic safety signal Dyn Robot controller with robot s C Emergency stop two channel poten tial free ES FlexLoader function package D Protective stop two channel poten tial free PS Equipment with elevated risk level e g deburring cutting air cleaning E Connected system K FlexLoader Standard Safety F 20 Application manual FlexLoader Standard...

Page 21: ...ernal safety connections see Internal safety interface on page 38 External safety connections Connection to the machine tool or other external safety equipment must be carried out according to the wiring diagram All safety functions must be tested after installation before the machine is used for the first time For general information on external safety connections see External safety interface to...

Page 22: ...ch a way that the safety level PLd can also be fulfilled for the combined system on the condition that the external equipment fulfils PLd In order for the external equipment in the safety function emergency stop of all equipment to fulfil the PLd the equipment must fulfil all PLd requirements In order for the external equipment in the safety function protective stop of all equipment to fulfil the ...

Page 23: ...ate network in RobotStudio Use Controller Configuration Modify IP settings to fit the pricate network 1 Configure devices for your robot controller in RobotStudio I O configurator IOC Use Controller Configuration 2 Import all necessary GSDML files or modify the IPPNIO xml file Locate devices with the RobotStudio ScanTool and add relevant devices to the con troller Modify names and addresses if nec...

Page 24: ...ed in robot I O configurator Internal cell network The internal cell network connects the FlexLoader Vision PC robot safety devices I O devices frequency converters and other internal cell components to each other This network is the robots private network and both robot LAN2 and LAN3 as well as the service port are connected to this network The robot is acting as PROFINET master Tip The FlexLoade...

Page 25: ...192 168 125 151 PLC camera 1 e g plc fp300 192 168 125 1 192 168 125 152 PLC camera 2 e g plc fp400 192 168 125 1 192 168 125 153 PLC camera 3 e g plc fp600 192 168 125 1 192 168 125 154 PLC camera 4 gatepn 192 168 125 1 192 168 125 160 Pluto gateway ci502 pn 01 192 168 125 1 192 168 125 161 I O board 1 e g ci502 pn 09 192 168 125 1 192 168 125 169 I O board 9 e g bufferbelt2 separ ationbelt camer...

Page 26: ...FINET by using a PROFINET fieldbus adapter in the second controller robot option 840 3 xx1800002906 A master PLC be connected through PROFINET by using a PROFINET fieldbus adapter in the first controller robot option 840 3 xx1800002905 Continues on next page 26 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 3 Installation ...

Page 27: ...e WAN port as well with all internal network components connected to WAN instead of LAN2 However this will expose all components to an external network We recommend to avoid this system setup Application manual FlexLoader Standard Safety Center 27 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 3 Installation Continued ...

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Page 29: ...or switches and any other safety devices Other safety devices can include e g light guards external machine actuators pneumatic safety valves SafeMove restrictions and laser scanners Check the safety sensors and actuators What Check the safety sensors and actuators When Every month How In the event of wear or damage the breaker key switch magnetic lock or other safety related parts must be replace...

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Page 31: ... stop PS Connected system K The connected system s must achieve sufficiently high PL performance level and PFH values average probability of dangerous failures per hour in order to achieve the necessary PL for all affected safety functions It is generally recommended that all protective functions are internally monitored and doubled The emergency stop and protective stop on FlexLoader Standard Saf...

Page 32: ... Standard Safety Center can be configured to accept a dynamic signal instead FlexLoader Standard Safety Center is always the protective stop master The connected system is emergency stop master Emergency stop is transmitted via a potential free two channel signal to the connected system acting as an emergency stop button xx1800002553 Continues on next page 32 Application manual FlexLoader Standard...

Page 33: ...y Center xx1800000176 Description Pos Connected system is emergency stop master A FlexLoader Standard Safety Center receiving a two channel potential free signal B The connected system is responsible for resetting the emergency stop FlexLoader Standard Safety Center resets the emergency stop automatically Continues on next page Application manual FlexLoader Standard Safety Center 33 3HAC051769 001...

Page 34: ...tial free signal to FlexLoader Standard Safety Center acting as an emergency stop button xx1800002558 Continues on next page 34 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 5 Interface 5 1 External safety interface to connected system Continued ...

Page 35: ...stem xx1800000176 Description Pos FlexLoader Standard Safety Center is emergency stop master A Connected system receiving a two channel potential free signal B FlexLoader Standard Safety Center is responsible for resetting the emergency stop The connected system resets the emergency stop automatically Continues on next page Application manual FlexLoader Standard Safety Center 35 3HAC051769 001 Rev...

Page 36: ...nter is responsible for resetting its own emergency stop Other masters transmit the emergency stop via a two channel potential free signal to the FlexLoader Standard Safety Center Emergency stop for further masters in the system is transmitted by signalling a 2 second emergency stop This is to avoid locking modes in the emergency stop circuits In a system with several masters each master is respon...

Page 37: ...ncy command can be issued from the master that already is in emergency stop This behavior depends on the exact emergency stop implementation in the connected master systems and must be risk assessed for every cell Application manual FlexLoader Standard Safety Center 37 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 5 Interface 5 1 External safety interface to connected syste...

Page 38: ...ES FlexLoader function package D Protective stop two channel poten tial free PS Equipment with elevated risk level e g deburring cutting air cleaning E Door safety chain Door openings are safeguarded by Eden DYN safety switches Up to three serial Eden DYN switches which can be Magne units with integrated magnetic locking can be directly connected to the FlexLoader There are two basic versions of t...

Page 39: ...he wiring diagram Emergency stop chain All internal emergency stop buttons and functions are connected to FlexLoader Standard Safety Center in a single two channel potential free signal chain This includes the robot and the feeders The cables are connected to terminals in the FlexLoader cabinet For more detailed information see the wiring diagram Safety interface to robot Emergency stop Internal e...

Page 40: ...cabinet For more detailed information see the wiring diagram Protective stop There is no protective stop to the FlexLoader function package e g FlexLoader FP 400 or FlexLoader FP 600 Interface to dangerous equipment Emergency stop No separate emergency stop is transmitted to other dangerous equipment The emergency stop is handled through the protective stop interface Protective stop Protective sto...

Page 41: ...sion channels are provided as shown below We recommend the use of the following valve Festo MS6 SV 1 2 D 10V24P 2M8 SO AD1 or compatible xx1900001048 Figure 5 1 Application manual FlexLoader Standard Safety Center 41 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 5 Interface 5 2 Internal safety interface Continued ...

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Page 43: ...ntry request and locking management are non safety rated functions that are normally checked and controlled by the robot They are not part of the FlexLoader Standard Safety Center The robot is responsible for locking the door when necessary The FlexLoader Standard Safety Center provides a possibility to override door locking in case of emergency stop or protective stop Controlled exit The protecti...

Page 44: ...dant combined with the reset key switch at a door A dedicated risk analysis must be performed prior to using this functionality 44 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 6 Function description Continued ...

Page 45: ... the door status by shortly turning the reset key Optionally if a light curtain is present a long light curtain reset may be needed 0 5 s first followed by a second reset for the whole cell 3 Check the function of the external emergency stop 4 Check the function of the external protective stop if present DANGER Do not continue to work until the safety circuits are functioning correctly Application...

Page 46: ...s Emergency stop A Start button integrator dependent B Entry request button C Key switch D Emergency stop reset button if master E Protective stop Request entry to the robot cell through routines provided by the robot program DANGER When entering the cell the operator must bring the key that is used to confirm the protection door This is to prevent somebody else from confirming and restarting Flex...

Page 47: ...d Restart the robot cell through routines provided by the robot program Manual operation of dangerous equipment By default the protective stop is activated as soon as any FlexLoader Standard Safety Center door is opened This deactivates dangerous equipment in the cell Sometimes such equipment must be activated for test operation Therefore the FlexLoader Standard Safety Center electrical cabinet al...

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Page 49: ... dangerous components and potentially hazardous materials Disposal of storage media Before disposal of any storage equipment anything from an SD card to a complete controller make sure that all sensitive information has been deleted Application manual FlexLoader Standard Safety Center 49 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved 8 Decommissioning 8 1 General ...

Page 50: ...inappropriate waste handling For disposal in countries outside of the European Union The crossed out wheeled bin symbol is only valid in the European Union EU and means that used electrical and electronic equipment WEEE should not be mixed with general household waste If you wish to discard this product please contact your local authorities or dealer and ask for the correct method of disposal Disp...

Page 51: ...o prevent health or environmental hazards Example application Material Main computer Batteries Lithium Serial measurement board Cables Copper Motors Cabinet structure plates screws etc Steel Cables connectors etc Plastic rubber PVC Heat sinks on power supplies and drive units Aluminium Electronics Lead Electronics Brominated flame retardants Gearboxes Oil grease Motors Neodymium brakes Application...

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Page 53: ...e external protective stop can be supplied as a single channel dynamic signal e g Eden IsDynamicExternalAutostop In this case the correct polarity on input I0 2 must be defined in the I O configuration If necessary a controlled exit of the cell is required IsControlledExit In this case the signal ControlledExitButton must be pulsed by pressing a suitably placed button at most 30 s prior to activat...

Page 54: ...that can ensure that the door always unlocks regardless of the robot s lock command If any of the safe outputs is set to 0 the output EnableLockDoor is also set to 0 EnableLockDoor is only set to 1 when all safe outputs are set to 1 It can be used to route a lock signal from the robot through a relay Protective stop safety function of dangerous equipment During an ongoing protective stop the outpu...

Page 55: ...the emergency stop output OutEmergencyStopInternal is reset to 1 Protective stop can then be reset according to the rules for protective stop Emergency stop Pluto is master In this operating mode the external emergency stop is evaluated as if it was an emergency stop button The emergency stop to the external equipment comes from the emergency stop relays outputs The emergency stop must be reset on...

Page 56: ... the internal emergency stop cause is rectified when the signals InEmergencyStopExternalChA B become 1 again the safe outputs OutEmergencyStopInternal can be set to 1 A condition for the safe outputs OutEmergencyStopExternal to be returned to 1 is that the supervision signal from the expansion relay SupervisionEmergencyStopExternal is 1 OutEmergencyStopExternal must be 0 for at least 2 seconds eve...

Page 57: ...ncy stop is active and the protective stop circuit is broken Error code 77 Error when selecting basic configuration None or several of the basic configurations have been selected Only select one during transfer In the event of a two channel fault in one of the two channel inputs one of the associated inputs flashes Two channel faults occur when for example only one channel is activated and then re...

Page 58: ...rChain having been set to both 0 and to 1 Pluto is in the initiation sequence after start from a non powered status The protective stop chain and internal emergency stop chain must be interrupted once and reset The value indicates Pluto s basic configuration For more information see Operation on page 45 Even number of doors switches Odd number of doors switches Configuration 97 94 Pluto as slave 9...

Page 59: ... not used InMotorsOnChB I 7 Reset protective stop static ResetAutoStop IQ 10 Reset emergency stop DynA NonInv option ResetEmergencyStop ResetEmergencyStopLamp IQ 11 IQ 11 Lamp in reset button static option Protective stop in door chain Even numbers of doors DynA Noninv Odd numbers of doors DynA AutoStopDoorChain IQ 12 Supervision expansion protective stop static SupervisionAutoStop IQ 13 Supervisi...

Page 60: ...nalRiskCompon ents Q 1 Protective stop for both internal and ex ternal equipment via expansion relay OutAutoStopInternalExternal Q 2 Emergency stop for internal equipment via expansion relay OutEmergencyStopInternal Q 3 60 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved A Technical data A 5 Pluto I O Continued ...

Page 61: ...2 Base 16 ms Eden DYN Magne safety switch 30 ms Resulting system stop times Typical total response times for initiating robot stop motion Protective stop due to light beam violation 61 5 ms 16 ms 20 5 ms 5 ms 20 ms Protective stop due to door opening violation 75 5 ms 30 ms 20 5 ms 5 ms 20 ms Typical response times for external emergency stop External emergency or protective stop transfer to other...

Page 62: ... the Pluto program Configuring 1 Ensure that the programming cable is connected between the computer and Pluto 0 2 Open the desired program in Pluto Manager There are two basic versions of the Pluto program One for an even number of serially connected Eden DYN switches in the protective stop chain PlutoStandardEven and another for an odd number of serially connected Eden DYN switches in the protec...

Page 63: ...K to confirm your selection of Pluto behavior Repeat until all options are set according to the specification xx1800000424 7 The next step is to compile the program Click Comp xx1800000425 Continues on next page Application manual FlexLoader Standard Safety Center 63 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved A Technical data A 7 Installation guide Continued ...

Page 64: ...twice at the first download Always enter the password svia when downloading For later downloading the correct password must be used to download a new program in Pluto xx1800000428 Continues on next page 64 Application manual FlexLoader Standard Safety Center 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved A Technical data A 7 Installation guide Continued ...

Page 65: ...efore click Yes to restart execution xx1800000429 4 Perform the same sequence as at restart from unpowered status Application manual FlexLoader Standard Safety Center 65 3HAC051769 001 Revision E Copyright 2014 2020 ABB All rights reserved A Technical data A 7 Installation guide Continued ...

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Page 68: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC051769 001 Rev E en Copyright 2014 2020 ABB All rights reserved Specifications subject to change without notice ...