3URGXFWPDQXDOSURFHGXUHV

5RERWFRQWUROOHU

S4Cplus
M2000
3URGXFWPDQXDOSURFHGXUHV
3HAC 021333-001
Revision A

Robot controller
S4Cplus
M2000
The information in this manual is subject to change without notice and should not be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fit-
ness 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 per-
mission, and contents thereof must not be imparted to a third party nor be used for any unau-
thorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2004 ABB All right reserved.

ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden
 7DEOHRI&RQWHQWV

0.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0.0.2 Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
0.0.3 Reading the Product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6DIHW\VHUYLFH 
1.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
*HQHUDOLQIRUPDWLRQ 
1.1.1 Safety, service - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6DIHW\ULVNV 
1.2.1 Safety risks related to gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.5 Safety risks during installation and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6DIHW\DFWLRQV 
1.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.7 Work inside the manipulator’s working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

'HVFULSWLRQFRQWUROV\VWHP 
2.0.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
&RPSXWHUV\VWHP 
2.1.1 Computer system interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.1.2 Main computer board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1.3 Axis computer board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1.4 I/O computer board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1.5 Optional boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6HUYRV\VWHP 
2.2.1 Servo system, principle function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2.2 Regulation and control of robot movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2.3 Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
,2V\VWHP 
2.3.1 I/O system overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6DIHW\V\VWHP 
2.4.1 Safety system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.2 The chain of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.3 MOTORS ON and MOTORS OFF modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.4 Safeguarded space stop signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.5 Limitation of velocity during programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4.6 ENABLE signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.7 Supervision of 24 V supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.8 Monitoring of safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
([WHUQDOD[HV 
2.5.1 External axes (Not for IRB 340!) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3HAC 021333-001 3
7DEOHRI&RQWHQWV

,QVWDOODWLRQDQGFRPPLVVLRQLQJ 
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8QSDFNLQJ 
3.2.1 Transporting and unpacking, S4Cplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2QVLWH,QVWDOODWLRQ 
3.3.1 Lifting the controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3.2 Required installation space, control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3.3 Bolt pattern, control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3.4 Installation of external power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3.5 Installation of Distributed Drive Unit -VW (DDU-VW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
(OHFWULFDOFRQQHFWLRQV 
6LJQDO3RZHUFDEOHV
3.4.1.1 Connecting the manipulator to the control cabinet, S4Cplus cabling. . . . . . . . . . . . . . . . 62
3.4.1.2 Connectors on control cabinet, S4Cplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.4.1.3 Connectors on the distributed drive unit, DDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4.1.4 Connection of mains power to control cabinet, S4Cplus . . . . . . . . . . . . . . . . . . . . . . . . . 67
6LJQDOFRQQHFWLRQV
3.4.2.1 Signal Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4.2.2 Selecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.4.2.3 Coil neutralization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4.2.4 Connection types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.4.2.5 Connections to screw terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4.2.6 Connections to connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
&XVWRPHUFRQQHFWLRQVRQFRQWUROOHU
3.4.3.1 The MOTORS ON/MOTORS OFF circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.3.2 External customer connections on panel X1 - X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.4.3.3 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6XSSOLHV
3.4.4.1 External 24V supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.4.4.2 24V I/O supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.4.4.3 115/230 VAC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
%XVHV
3.4.5.1 Connection of the DeviceNet bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.4.5.2 DeviceNet Bus status LED description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4.5.3 RIO, remote I/O for Allen-Bradley PLC DSQC 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.4.5.4 1 Interbus-S, slave DSQC 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.4.5.5 Profibus-DP, slave DSQC 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
,2XQLWV 
3.4.6.1 Distributed I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.4.6.2 Distributed I/O, digital sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4.6.3 Distributed I/O, digital I/O DSQC 328 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.4.6.4 AD Combi I/O, DSQC 327 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4.6.5 Analog I/O, DSQC 355 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.4.6.6 Encoder interface unit, DSQC 354 (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.4.6.7 Queue tracking unit, DSQC 377 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.4.6.8 Relay I/O, DSQC 332 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.4.6.9 Digital I/O (120 VAC), DSQC 320 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
&RPPXQLFDWLRQ 
3.4.7.1 Communication, serial links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.4.7.2 Communication, Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.4.7.3 External operator’s panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6WDUWXS 
3.5.1 Inspection before start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4 3HAC 021333-001
 7DEOHRI&RQWHQWV

3.5.2 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

,QVWDOODWLRQRIFRQWUROOHUVRIWZDUH  
3.6.1 Loading system software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.6.2 RobotWare CD-ROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.6.3 Installing new Robot Controller Software with RobInstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.6.4 Create a new Robot Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.6.5 Update the Robot Controller image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.6.6 Transfer Robot Controller System using Ethernet connection. . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.6.7 Transfer Robot Controller System using floppy disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.6.8 RobInstall preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5RERWFRQWUROOHU  
3.7.1 BootImage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.7.2 Start window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.7.3 Reboot Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.7.4 Boot Disk Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.7.5 Network Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.7.6 LAN Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.7.7 Service Settings Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.7.8 System selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.7.9 How to perform a Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.7.10 How to Start in Query Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6\VWHPGLUHFWRU\VWUXFWXUH  
3.8.1 Media pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.8.2 System pool in the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.8.3 File structure in the robot controller mass storage memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.8.4 Preparation of S4Cplus software to be installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.8.5 Handling mass memory storage capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

0DLQWHQDQFH 
4.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
0DLQWHQDQFHVFKHGXOH 
4.1.1 Maintenance schedule, controller S4CPlus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
,QVSHFWLRQDFWLYLWLHV 
4.2.1 Inspection of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
&OHDQLQJDFWLYLWLHV  
4.3.1 Cleaning of controller cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.3.2 Cleaning air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5HSODFHPHQWDFWLYLWLHV  
4.4.1 Replacement of CMOS battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.4.2 Replacement of drive system fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.4.3 Replacement of battery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.4.4 Replacement of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.4.5 Replacement of fan unit in computer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

5HSDLU 
5.0.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
&RPSOHWHFRQWUROOHUFDELQHW  
5.1.1 Putting the computer system in service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.1.2 Replacement of I/O and gateway units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5.1.3 Replacement of bleeder resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5.1.4 Replacement of mass storage memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5.1.5 Replacement of internal cooling fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.1.6 Replacement of drive units and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

3HAC 021333-001 5
7DEOHRI&RQWHQWV

5.1.7 Replacement of power supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU 
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
.LQHPDWLFPRGHOV 
6.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.2.2 Kinematic model X_Y_Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
6.2.3 Kinematic model X_Y_Z_C(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
6.2.4 Kinematic model X_Y_Z_B(X). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.2.5 Kinematic model X_Y_Z_B(Y). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.2.6 Kinematic model X_Y_Z_B(X)_A(Z). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.2.7 Kinematic model X_Y_Z_B(Y)_A(Z). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.2.8 Kinematic model X_Y_Z_C(Z)_B(X)_A(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
6.2.9 Kinematic model Y_Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
6.2.10 Kinematic model Y_Z_C(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.2.11 Kinematic model Y_Z_B(X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
6.2.12 Kinematic model Y_Z_B(Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
6.2.13 Kinematic model Y_Z_B(X)_A(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
6.2.14 Kinematic model Y_Z_B(Y)_A(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
6.2.15 Kinematic model Y_Z_C(Z)_B(X)_A(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
6.2.16 Kinematic model Y_E(Y)_D(Y)_C(Y)_B(Y)_A(Z) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
6.2.17 Doppin Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
&RQILJXUDWLRQ 
6.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
0LQLPDOFRQILJXUDWLRQ 
6.3.2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
6.3.2.2 External configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
6.3.2.3 Internal configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3DUDPHWHUGHVFULSWLRQ
6.3.3.1 Description of ingoing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
6.3.3.2 MOTION_SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.3.3.3 MECHANICAL_UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
6.3.3.4 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
6.3.3.5 ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.3.3.6 MEASUREMENT_CHANNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.3.3.7 ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.3.3.8 ARM_TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
6.3.3.9 ACC_DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
6.3.3.10 ARM_CALIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
6.3.3.11 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
6.3.3.12 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
6.3.3.13 BRAKE_TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
6.3.3.14 SUPERVISION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
6.3.3.15 SUPERVISION_TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
6.3.3.16 DRIVE_SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
6.3.3.17 CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
6.3.3.18 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
6.3.3.19 MOTOR_TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
6.3.3.20 MOTOR_ CALIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
6.3.3.21 THERMAL_DUTY_CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
6.3.3.22 STRESS_DUTY_CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
6.3.3.23 UCCM0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
6.3.3.24 LCM0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
6.3.3.25 LINEAR_JOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

6 3HAC 021333-001
 7DEOHRI&RQWHQWV

6.3.3.26 REORIENT_JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

6.3.3.27 JOINT_JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
7XQLQJ  
6.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
6.4.2 Tuning of axes, complete procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
6.4.3 Defining signals in Test Signal Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
6.4.4 Initial tuning of Kv, Kp and Ti. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
6.4.5 Specifying the inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
6.4.6 Tuning of bandwith . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.4.7 Tuning of resonance_frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
6.4.8 Tuning of wc_acc and wc_dec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
6.4.9 Final tuning of Kp, Kv and Ti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
)LOHKDQGOLQJFRQILJXUDWLRQDQGHUURUPDQDJHPHQW 
6.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.5.2 File handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
6.5.3 How to use a Hyper Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
6.5.4 Error management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

3HAC 021333-001 7
7DEOHRI&RQWHQWV

8 3HAC 021333-001
 0.0.1 Overview

2YHUYLHZ

$ERXWWKLV This manual contains instructions for

PDQXDO • mechanical and electrical installation of the controller
• maintenance of the controller
• mechanical and electrical repair of the controller.

8VDJH This manual should be used during

• installation, from lifting the controller to its work site to making it ready for operation
• maintenance work
• repair work.

:KRVKRXOGUHDG This manual is intended for:

WKLVPDQXDO" • installation personnel
• maintenance personnel
• repair personnel.

3UHUHTXLVLWHV The reader should...

• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/mainte-
nance work.

2UJDQL]DWLRQRI The manual is organized in the following chapters:

FKDSWHUV

&KDSWHU &RQWHQWV
Safety Important safety information for all service work done
with the control cabinet
System description General description of the control system
Installation and commissioning Descriptions of mechanical installation, electrical con-
nections and loading system software
Maintenance Descriptions of all required preventive maintenance
procedures including periodicity
Repair Descriptions of all recommended repair procedures
including spare parts
IRC S4Cplus - control of non-ABB Descriptions of kinematic models, tuning procedure
manipulator and system parameters - used for robot systems
including a non-ABB manipulator

3HAC 021333-001 A 9

0.0.1 Overview

5HIHUHQFHV

5HIHUHQFH 'RFXPHQW,G

5HYLVLRQV

5HYLVLRQ 'HVFULSWLRQ
- First edition.
This Product Manual replaces the documentation for
the control cabinet S4Cplus, previously implemented
with the manipulator documentation.
Changes made in the material from the previous man-
uals:
• New chapter ,5&6&SOXV&RQWURORIQRQ$%%
PDQLSXODWRU on page 223 added.
• Various corrections and completings made
throughout the manual.
A Changes made in the material from the previous revi-
sion:
• In chapter &UHDWHDQHZ&RQWUROOHU6\V
WHP6WHStext about name lenght of max. 16
characters added.

10 A 3HAC 021333-001
 0.0.2 Product Documentation

3URGXFW'RFXPHQWDWLRQ

*HQHUDO The complete product documentation kit for the robot, including controller, manipulator and
any hardware option, consists of the manuals listed below:

+DUGZDUH All hardware, manipulators and controller cabinets, will be delivered with a 3URGXFW0DQXDO
PDQXDOV that is divided into two parts:
3URGXFWPDQXDOSURFHGXUHV
• Safety information
• Installation and Commissioning (descriptions of mechanical installation, electrical con-
nections and loading system software)
• Maintenance (descriptions of all required preventive maintenance procedures includ-
ing periodicity)
• Repair (descriptions of all recommended repair procedures including spare parts)
• Additional procedures, if any (calibration, decommissioning).
3URGXFWPDQXDOUHIHUHQFHLQIRUPDWLRQ
• Reference information (article numbers for documentation refered to in Product man-
ual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams.

6RIWZDUHPDQXDOV The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during oper-
ation.
A complete listing of all available software manuals is available from ABB.

+DUGZDUHRSWLRQ Each hardware option is supplied with its own documentation. Each document set contains
PDQXDO the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

3HAC 021333-001 A 11

0.0.2 Product Documentation

12 A 3HAC 021333-001
 0.0.3 Reading the Product manual

5HDGLQJWKH3URGXFWPDQXDO

*HQHUDO This section contains useful information about how to read the product manual.

5HDGLQJWKH The references made from instructions are followed as described below:
LQVWUXFWLRQV

5HIHUHQFHVWRILJ The instructions often include references to components or attachment points located on the
XUHV manipulator. The components or attachment points are marked with LWDOLFWH[W in the instruc-
tions and completed with a reference to the figure where the current component or attachment
point is shown.
The chosen denomination in the instruction for the component or attachment point corre-
sponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an instruction.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Remove the UHDUDWWDFKPHQW Shown in the figure /RFDWLRQRIJHDUER[.
VFUHZVJHDUER[

5HIHUHQFHVWR The instructions often also include references to equipment (spare parts, tools etc.) required
UHTXLUHGHTXLS for the different actions in the instruction. The equipment is marked with LWDOLFWH[W in the
PHQW instructions and completed with a reference to the section where the equipment is listed with
further information, i.e. article number, dimension.
The chosen denomination in the instruction for the equipment corresponds to the denomina-
tion in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an instruction.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Fit a new VHDOLQJD[LV to the Art. no. is specified in 5HTXLUHGHTXLSPHQW.
gearbox.

'DQJHUOHYHOV The table below defines the captions specifying the danger levels used thoughout this manual.

6\PERO 'HVLJQDWLRQ 6LJQLILFDWLRQ

DANGER warns that an accident ZLOO occur if the instructions are not
followed, resulting in a serious or fatal injury and/or severe
damage to the product. It applies to warnings that apply to
danger danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height etc.

3HAC 021333-001 A 13

0.0.3 Reading the Product manual

6\PERO 'HVLJQDWLRQ 6LJQLILFDWLRQ

WARNING warns that an accident PD\ occur if the instructions are not
followed, that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
warning
to danger with, for example, contact with high voltage electri-
cal units, explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height etc.
CAUTION warns that an accident may occur if the instructions are not
followed, that can result in injury and or damage to the prod-
uct. It also applies to warnings of risks that include burns, eye
injury, skin injury, hearing damage, crushing or slipping, trip-
caution
ping, impact, fall from height etc. Furthermore, it applies to
warnings that include function requirements when fitting and
removing equipment, where there is a risk of damaging the
product or causing a breakdown.
NOTE

Note

TIP

Tip

14 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.0.1 Introduction

6DIHW\VHUYLFH
,QWURGXFWLRQ

'HILQLWLRQV This chapter details safety information for service personnel i.e. personnel performing instal-
lation, repair and maintenance work.

6HFWLRQV The chapter "Safety, service" is divided into the following sections:
 *HQHUDOLQIRUPDWLRQ contains lists of:
• Safety, service -general
• Limitation of liability
• Referenced documents
 6DIHW\ULVNV lists dangers relevant when servicing the robot system. The dan-
gers are split into different categories:
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
 6DIHW\DFWLRQV details actions which may be taken to remedy or avoid dangers.
• Safety fence dimensions
• Fire extinguishing
• Emergency release of the manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
• Work inside the manipulator´s working range

3HAC 021333-001 A 15
6DIHW\VHUYLFH
1.1.1 Safety, service - General

*HQHUDOLQIRUPDWLRQ

6DIHW\VHUYLFH*HQHUDO

9DOLGLW\DQG The information does not cover how to design, install and operate a complete system, nor
UHVSRQVLELOLW\ does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the indus-
trial robot, described in the applicable documents, e.g. User’s Guide and Product Manual.

&RQQHFWLRQRI Apart from the built-in safety functions, the robot is also supplied with an interface for the
H[WHUQDOVDIHW\ connection of external safety devices. Via this interface, an external safety function can inter-
GHYLFHV act with other machines and peripheral equipment. This means that control signals can act on
safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for con-
necting safety devices between the robot and the peripheral equipment.

16 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.1.2 Limitation of Liability

/LPLWDWLRQRI/LDELOLW\

*HQHUDO Any information given in this information product regarding safety, must not be construed as
a warranty by ABB that the industrial robot will not cause injury or damage even if all safety
instructions have been complied with.

3HAC 021333-001 A 17
6DIHW\VHUYLFH
1.1.3 Related information

5HODWHGLQIRUPDWLRQ

*HQHUDO The list below specifies documents which contain useful information:

'RFXPHQWV

7\SHRILQIRUPDWLRQ 'HWDLOHGLQGRFXPHQW 6HFWLRQ

Installation of safety devices Product manual for the Installation and Commissioning
manipulator
Changing robot modes User’s Guide Start-up
Restricting the working space Product manual for the Installation and Commissioning
manipulator

18 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.2.1 Safety risks related to gripper

6DIHW\ULVNV

6DIHW\ULVNVUHODWHGWRJULSSHU
Ensure that a gripper is prevented from dropping a workpiece, if such is used.

3HAC 021333-001 A 19
6DIHW\VHUYLFH
1.2.2 Safety risks related to tools/workpieces

6DIHW\ULVNVUHODWHGWRWRROVZRUNSLHFHV

6DIHKDQGOLQJ It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).

6DIHGHVLJQ Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.

20 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.2.3 Safety risks related to pneumatic/hydraulic systems

6DIHW\ULVNVUHODWHGWRSQHXPDWLFK\GUDXOLFV\VWHPV

*HQHUDO Special safety regulations apply to pneumatic and hydraulic systems.

5HVLGXDOHQHUJ\ • Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.

6DIHGHVLJQ • Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

3HAC 021333-001 A 21
6DIHW\VHUYLFH
1.2.4 Safety risks during operational disturbances

6DIHW\ULVNVGXULQJRSHUDWLRQDOGLVWXUEDQFHV

*HQHUDO • The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.

4XDOLILHGSHU • Remedial action must only be carried out by qualified personnel who are familiar with
VRQQHO the entire installation as well as the special risks associated with its different parts.

([WUDRUGLQDU\ If the working process is interrupted, extra care must be taken due to risks other than those
ULVNV associated with regular operation. Such an interruption may have to be rectified manually.

22 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.2.5 Safety risks during installation and service

6DIHW\ULVNVGXULQJLQVWDOODWLRQDQGVHUYLFH

*HQHUDOULVNV • The instructions in the Product Manual - Installation and Commissioning must always
GXULQJLQVWDO be followed.
ODWLRQDQGVHUYLFH • Emergency stop buttons must be positioned in easily accessible places so that the
robot can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available
for the installation in question.
• Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.

1DWLRQUHJLRQ To prevent injuries and damage during the installation of the robot system, the regulations
VSHFLILFUHJXOD applicable in the country concerned and the instructions of ABB Robotics must be complied
WLRQV with.

1RQYROWDJH • Safety zones, which have to be crossed before admittance, must be set up in front of
UHODWHGULVNV the robot's working space. Light beams or sensitive mats are suitable devices.
• Turntables or the like should be used to keep the operator out of the robot's working
space.
• The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
• Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the robot as a ladder, i.e. do not climb on the robot motors or other parts
during service work. There is a serious risk of slipping because of the high tempera-
ture of the motors or oil spills that can occur on the robot.

7REHREVHUYHG • The supplier of the complete system must ensure that all circuits used in the safety
E\WKHVXSSOLHURI function are interlocked in accordance with the applicable standards for that function.
WKHFRPSOHWH • The supplier of the complete system must ensure that all circuits used in the emer-
V\VWHP gency stop function are interlocked in a safe manner, in accordance with the applica-
ble standards for the emergency stop function.

3HAC 021333-001 A 23
6DIHW\VHUYLFH
1.2.6 Risks associated with live electric parts

5LVNVDVVRFLDWHGZLWKOLYHHOHFWULFSDUWV

9ROWDJHUHODWHG • Although troubleshooting may, on occasion, have to be carried out while the power
ULVNVJHQHUDO supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.

9ROWDJHUHODWHG A danger of high voltage is associated with the following parts:

ULVNVFRQWUROOHU • Be aware of stored electrical energy (DC link) in the controller.
• Units inside the controller, e.g. I/O modules, can be supplied with power from an exter-
nal source.
• The mains supply/mains switch
• The power unit
• The power supply unit for the computer system (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for tools, or special power supply units for the machining pro-
cess
• The external voltage connected to the control cabinet remains live even when the
robot is disconnected from the mains.
• Additional connections

9ROWDJHUHODWHG A danger of high voltage is associated with the manipulator in:

ULVNVPDQLSX • The power supply for the motors (up to 800 VDC)
ODWRU
• The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)

9ROWDJHUHODWHG Tools, material handling devices, etc., may be live even if the robot system is in the OFF
ULVNVWRROV position. Power supply cables which are in motion during the working process may be dam-
PDWHULDOKDQGOLQJ aged.
GHYLFHVHWF

24 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.3.1 Safety fence dimensions

6DIHW\DFWLRQV

6DIHW\IHQFHGLPHQVLRQV

*HQHUDO Fit a safety fence or enclosure around the robot to ensure a safe robot installation.

'LPHQVLRQLQJ Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.

3HAC 021333-001 A 25
6DIHW\VHUYLFH
1.3.2 Fire extinguishing

)LUHH[WLQJXLVKLQJ
Use a CARBON DIOXIDE (CO 2 ) extinguisher in the event of a fire in the robot (manipula-
tor or controller)!

26 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.3.3 Emergency release of the manipulator’s arm

(PHUJHQF\UHOHDVHRIWKHPDQLSXODWRU
VDUP

'HVFULSWLRQ In an emergency situation, any of the manipulator’s axes may be released manually by push-
ing the brake release buttons on the manipulator or on an optional external brake release unit.
How to release the brakes is detailed in section "Manually releasing the brakes".
The manipulator arm may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar.

,QFUHDVHGLQMXU\ Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, which may further increase any injury!

3HAC 021333-001 A 27
6DIHW\VHUYLFH
1.3.4 Brake testing

%UDNHWHVWLQJ

:KHQWRWHVW During operation the holding brakes of each axis motor wear normally. A test may be per-
formed to determine whether the brake can still perform its function.

+RZWRWHVW The function of each axis’ motor holding brakes may be checked as detailed below:
 Run each manipulator axis to a position where the combined weight of the manip-
ulator arm and any load is maximized (max. static load).
 Switch the motor to the MOTORS OFF position with the Operating mode selector
on the controller.
 Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.

28 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.3.5 Risk of disabling function "Reduced speed 250 mm/s"

5LVNRIGLVDEOLQJIXQFWLRQ5HGXFHGVSHHGPPV
1RWH
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.

3HAC 021333-001 A 29
6DIHW\VHUYLFH
1.3.6 Safe use of the Teach Pendant Unit

6DIHXVHRIWKH7HDFK3HQGDQW8QLW
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)
which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
During programming and testing, the enabling device must be released as soon as there is no
need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when entering the
robot’s working space. This is to prevent anyone else taking control over the robot without
the programmer knowing.

30 A 3HAC 021333-001
 6DIHW\VHUYLFH
1.3.7 Work inside the manipulator’s working range

:RUNLQVLGHWKHPDQLSXODWRU
VZRUNLQJUDQJH
:DUQLQJ
If work must be carried out within the robot’s work envelope, the following points must be
observed:
- The operating mode selector on the controller must be in the manual mode position to render
the enabling device operative and to block operation from a computer link or remote control
panel.
- The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in posi-
tion < 250 mm/s. This should be the normal position when entering the working space. The
position 100% ”full speed”may only be used by trained personnel who are aware of the risks
that this entails.
- Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order
not to get entangled with hair or clothing. Also be aware of any danger that may be caused by
rotating tools or other devices mounted on the manipulator or inside the cell.
- Test the motor brake on each axis, according to section %UDNHWHVWLQJ on page 28.

3HAC 021333-001 A 31
6DIHW\VHUYLFH
1.3.7 Work inside the manipulator’s working range

32 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.0.1 Overview

'HVFULSWLRQFRQWUROV\VWHP
2YHUYLHZ

*HQHUDO This chapter is an outline description of the robot controller system. It is intended as a help
for anyone needing a basic understanding of the control system and its main components.

3HAC 021333-001 A 33
'HVFULSWLRQFRQWUROV\VWHP
2.1.1 Computer system interfaces

&RPSXWHUV\VWHP

&RPSXWHUV\VWHPLQWHUIDFHV

,QFOXGHG The computer system is made up of three computers boards (shown in the illustration in
HTXLSPHQW section %ORFNGLDJUDP on page 35).
• Main Computer Board
• Axis Computer Board
• I/O Computer Board

%DVLFIXQFWLRQDO The computers are the data processing center of the robot and contain all the functions
GHVFULSWLRQ required to create, execute and store a robot program. They also contain functions for coor-
dinating and regulating the axis’ movements. The illustration in section %ORFNGLDJUDP on
page 35 shows how the computer system communicates with the other units.

34 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.1.2 Main computer board

%ORFNGLDJUDP The illustration shows an overview of the computer system within system S4Cplus.
Serial ports
1
Flash disk Ethernet MC/CONSOLE ,
2
(LAN) COM1

Floppy disk drive

(option) SMBus
Battery unit
Main computer

Computer power supply

Cooling fans Status signal

Status signal Process power supply

Test inputs
Measurement system 1
Axis computer Drive system 1
(several) Measurement system 2
Drive system 2
Enable 2

3 3
Serial channels COM2 , COM3
TPU
Ethernet (Service)
Enable 1

Panel unit
PCI bus I/O computer
CAN
Gateway units (option)

I/O units (option)

CAN

I/O units (option)

Gateway units (option)

Optional board (0-5)

Field bus (option)

xx0300000233

2 The COM1 port was formerly known as &RP.

3 The COM2 and COM3 ports were formerly known as 6,2and 6,2.

0DLQFRPSXWHUERDUG

'HVFULSWLRQ The Main Computer Board holds the robot system main computer and controls the entire
robot (Man-Machine Interface, execution of RAPID programs, path control of the robot).

3HAC 021333-001 A 35
'HVFULSWLRQFRQWUROV\VWHP
2.1.3 Axis computer board

$[LVFRPSXWHUERDUG

'HVFULSWLRQ The axis computer regulates the speed and position of up to seven axes as described below:
1. Set points for positions are sent from the main computer to the axis computer.
2. The axis computer receives position set values from the main computer and current
position from the serial measurement board.
3. The axis computer uses this data in regulating algorithms.
4. It then transmits the torque set value and the position values to the drive system.

,2FRPSXWHUERDUG

'HVFULSWLRQ This is the link between the main computer and the process equipment, e.g I/O units.

2SWLRQDOERDUGV

([WUDD[LVFRP These are required for control of additional external axes. Also an additional connector board
SXWHUV is required.

([WUD,2FRP These are required for extra I/O channels (CAN buses, Ethernet, Serial ports). Also an addi-
SXWHU tional connector board is required.

)LHOGEXVERDUGV Examples of such include: Profibus DP, Interbus-S.

36 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.2.1 Servo system, principle function

6HUYRV\VWHP

6HUYRV\VWHPSULQFLSOHIXQFWLRQ

*HQHUDO The servo system is a complex system comprising several different interacting hardware and
software units and system parts.
The servo function comprises:
• Digital regulation of the position, velocity and motor current of the robot axes
• Synchronous AC operation of the robot motors.

5HJXODWLRQDQGFRQWURORIURERWPRYHPHQWV

5HJXODWLRQ The regulation process is described below, and shown in the figure in section ,OOXVWUDWLRQ on
page 38:
1. During program execution, new robot axes' position data is continuously received from
the serial measurement board.
2. This data is received by the position regulator and compared with previous position
data.
3. The axis computer compares and amplifies the signal. The system holds a mathemat-
ical model of the robot to enable continuously calculating the optimal regulator param-
eters regarding gravity, moment of inertia and interaction between axes.
4. A new reference is given for the position and velocity of the robot.

&RQWURO The control process is described below, and shown in the figure in section ,OOXVWUDWLRQ on page
38:
1. A digital current reference for two phases is calculated based on the resolver signal and
a known relationship between the resolver angle and rotor angle. The third phase is
created from the other two.
2. The current of the three phases is regulated in the drive unit in separate current regu-
lators. In this way, three voltage references are returned which, by pulse-modulating
the rectifier voltage, are amplified to the working voltage of the motors.
3. The serial measurement board receives resolver data from a maximum of six (or
seven) resolvers and generates information on the position of the resolvers.

3HAC 021333-001 A 37
'HVFULSWLRQFRQWUROV\VWHP
2.2.3 Motor Overload

,OOXVWUDWLRQ The diagram outlines the system structure for AC operation as well as the fundamental struc-
ture of the drive unit.

Measurement system 1/2

Computer
Serial
measure
ment
Drive system 1/2 board

Drive
DC link unit /// M R x6 (7)

DC link

Torque Current M PWM

reference estimator U

W
Rotor M PWM M
position
V

M PWM

Power
circuits

en0300000234

0RWRU2YHUORDG

*HQHUDO PTC resistance is built into the robot motors to provide thermal protection against overloads.

)XQFWLRQ The PTC sensors are connected to a resistance sensitive input on the panel unit which moni-
tors and ensures that a low level of resistance is maintained. The robot computer checks the
motors for overloading at regular intervals by reading the panel unit register. In the event of
an overload, all the motors are switched off.

38 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.3.1 I/O system overview

,2V\VWHP

,2V\VWHPRYHUYLHZ

*HQHUDO The I/O system communicates with other equipment through digital and analog in- and output
signals.

,OOXVWUDWLRQ The illustration shows an outline of the I/O system.

Floppy
disk
Flash drive RS232
1
disk (option) COM1

Field bus master/slave boards

PCI bus Profibus DP
Main computer

Interbus-S

Ethernet
(service) TPU

I/O computer

RS232 RS422 CAN1 CAN2

2 2
COM2 COM3

16 in/16 out
I/O unit (s)

Safety signals
Panel unit

Gateway unit

I/O I/O I/O

en0300000235

1) The COM1 port was formerly known as &RP.

2) The COM2 and COM3 ports were formerly known as 6,2and 6,2.

3HAC 021333-001 A 39
'HVFULSWLRQFRQWUROV\VWHP
2.4.1 Safety system, description

6DIHW\V\VWHP

6DIHW\V\VWHPGHVFULSWLRQ

'HVFULSWLRQ The robot’s safety system is based on a two-channel safety circuit that is continuously moni-
tored. All switches in the two identical chains of switches must be closed. If the status of these
chains differ, the robot will remain in the MOTORS OFF mode.
The safety circuit consists of a combination of mechanical switches and software logic.
The function of the safety system and Motors ON/OFF circuit is further described in 7KH
027256210272562))FLUFXLW on page 76.

,OOXVWUDWLRQ The figure below illustrates an outline principle circuit with available customer contacts:

en0300000238

AS Automatic mode safetyguarded space stop

ED TPU Enabling Device
LS Limit switch
ES Emergency stop
GS General mode safeguarded space stop

40 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.4.2 The chain of operation

7KHFKDLQRIRSHUDWLRQ

*HQHUDO The chain of operation is made up of several safeguarded stop functions, located in the vicin-
ity of the manipulator. The aim of these are to make the area around the manipulator safe
while still enabling personnel to access it for maintenance and programming.

,QFOXGHGIXQF
WLRQV
8QLW )XQFWLRQ
Emergency stop buttons The emergency stop buttons on the operator’s panel, on the
Teach Pendant Unit (TPU) and external emergency stop buttons
are included in the two-channel chain of operation.
Auto Stop A safeguarded stop, AUTO STOP, which is active in the AUTO
operating mode, can be connected by the user. In any of the
MANUAL modes, the enabling device on the TPU overrides the
AUTO STOP.
General Stop The safeguarded stop GENERAL STOP is active in all operating
modes and is to be connected by the user.
Limit switch The limit switches are located at each end of each axis' range.
These may be adjusted to set the operative range for each axis.

%UHDNLQJWKH The sequence obtained by opening any of the units specified above is detailed below:
FKDLQ
 Any of the dual switches in the safety circuit are opened, breaking the circuit.
 The motor contactors drop out, cutting the power to the manipulator.
 The manipulator is stopped by the brakes.
 An interrupt call is sent directly from the panel unit to the computer system to
indicate the cause of the interruption.
 127( When the manipulator movement is stopped by a OLPLWVZLWFK, it may be
run by jogging it with the joystick while pressing the MOTORS ON button on the
TPU. The MOTORS ON button is monitored and may be depressed for a maxi-
mum of 30 seconds.

,QGLFDWLRQV LEDs for Emergency Stop, Automatic mode safeguarded space Stop and General mode safe-
guarded space Stop are connected to the two safety circuits to enable locating the broken

3HAC 021333-001 A 41
'HVFULSWLRQFRQWUROV\VWHP
2.4.2 The chain of operation

safety chain. The LEDs are located on the upper part of the panel unit. Status indication is
also available on the TPU display.

xx0100000283

A Interlocking
B Drive unit
C External contactors

42 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.4.3 MOTORS ON and MOTORS OFF modes

02725621DQG0272562))PRGHV

*HQHUDO The task of the safety circuit is to ensure that the robot goes to MOTORS OFF mode as soon
as the safety chain is broken. The computer system itself controls the last switch.

5HWXUQLQJWR When the safety chain is broken, switching the system to MOTORS OFF mode, there are a
02725621 number of methods to return it to MOTORS ON mode:
PRGH

,Q$872PRGH In AUTO mode, you can return the robot to MOTORS ON mode by pressing the MOTORS
ON button on the operator’s panel. If the circuit is OK, the computer system will close the
Solid state switch to close the circuit.
When switching to MANUAL from AUTO, the mode changes to MOTORS OFF and the
computer system opens the Solid state switch.

,Q0$18$/PRGH In any of the MANUAL modes, you can start operating again by pressing the enabling device
on the Teach Pendant Unit. If the circuit is OK, the computer system will close the Solid state
switch to complete the circuit.

6DIHJXDUGHGVSDFHVWRSVLJQDOV

*HQHUDO According to the safety standard ISO/DIS 11161 Industrial automation systems - safety of
integrated manufacturing systems - Basic requirements, there are two categories of safety
stops, category 0 and category 1. A safety analysis will show if category 0 or 1 is applicable.
All the robot's safety stops are category 0 stops as default. Safety stops of category 1 can be
obtained by activating the soft stop (delayed stop) together with Auto Stop or General Stop.
Activate by setting a parameter as described in the 8VHU
V*XLGH6\VWHP3DUDPHWHUV
7RSLF&RQWUROOHU.

&DWHJRU\ This is to be used when the power supply to the motors must be switched off immediately,
such as when a light curtain, used to protect against entry into the work cell, is passed. This

3HAC 021333-001 A 43
'HVFULSWLRQFRQWUROV\VWHP
2.4.5 Limitation of velocity during programming

uncontrolled motion stop may require special restart routines if the programmed path changes
as a result of the stop.

&DWHJRU\ This is preferred if acceptable, such as when gates are used to protect against entry into the
work cell. This controlled motion stop takes place within the programmed path, which makes
restarting easier.

/LPLWDWLRQRIYHORFLW\GXULQJSURJUDPPLQJ
Switch the operating mode switch to MANUAL REDUCED SPEED position when program-
ming the robot. This limits the robot’s maximum velocity to 250 mm/s.

44 A 3HAC 021333-001
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2.4.6 ENABLE signals

(1$%/(VLJQDOV

*HQHUDO ENABLE 1 and ENABLE 2 are signals to the panel unit from the I/O computer (EN1) and
axis computer (EN2).
The main computer monitors program execution of both the I/O computer and the axis com-
puter and can therefore affect both EN1 and EN2. Likewise, the I/O computer and the axis
computer monitor the program execution of the main computer.
If any computer detects an error, it will affect either one of EN1 and EN2.

(1$%/( EN1 is affected if an error occurs in the execution of the I/O computer program.

(1$%/( EN2 is affected if an error occurs in the execution of the axis computer program.

6XSHUYLVLRQRI9VXSSO\

*HQHUDO The safety circuit is supplied with 24 V.

)XQFWLRQ If the 24V supply to the safety circuits drops out, the MOTORS ON contactors will drop out,
causing the motors to switch off and a message will be displayed on the Teach Pendant Unit.

0RQLWRULQJRIVDIHW\FLUFXLW

*HQHUDO Monitoring of the external part of the safety circuits, including switches and operating con-
tacts, is carried out using both hardware and software. The hardware and software parts oper-
ate independently of each other.

0RQLWRUHG The following errors may be detected:

HTXLSPHQW • All inputs from the safety circuits are linked to registers, which allows the computer
system to monitor the status. If an interrupt occurs in the circuit, the status can be
read.
• If any of the switch functions are incorrectly adjusted, causing only one of the chains
of operation to be interrupted, the computer system will detect this. By means of hard-
ware interlocking it is not possible to enter MOTORS ON without correcting the cause.

6DPSOLQJWLPH The cyclic supervision of the safety control has a time limit of 2–4 seconds. This means that
when the first switch is opened, a period of 2–4 seconds is allowed for the second switch to
open.

3HAC 021333-001 A 45
'HVFULSWLRQFRQWUROV\VWHP
2.5.1 External axes (Not for IRB 340!)

([WHUQDOD[HV

([WHUQDOD[HV1RWIRU,5%

2XWOLQH External axes are controlled by drive units, mounted either inside the controller or externally
in a separate enclosure as shown in the figure below.
Depending on the robot type, a maximum of one or two drive units can be mounted inside the
controller. In addition to drive units from ABB, it is also possible to communicate with exter-
nal drive units from other vendors.
The figure below shows an outline diagram of the external axes possible to connect:
N ot s u pplie d onde live r y Motor chan ne l
S ingle E xternal Ax e s S erial s ig nals for
mea su re ment and
driv e sys tem

Me asu re me n t
S ys te m 1

N ot s u pplie d onde live r y

Multiple E x te rn al Axes

DDU

S MB

S MB
alt.

Me asu re m ent
S ys tem 2
Dri ve S ys tem 2

AB B Dr ive s

en0300000240

3DUWV  Motor channel

 Serial signals for measurement and drive system

46 A 3HAC 021333-001
 'HVFULSWLRQFRQWUROV\VWHP
2.5.1 External axes (Not for IRB 340!)

)XUWKHULQIRU For further information refer to 3URGXFW6SHFLILFDWLRQ6&SOXVand/or 8VHUV*XLGH([WHU

PDWLRQ QDOD[HV.
Art. no. for the manual is specified in section 'RFXPHQWUHIHUHQFHVin the 3URGXFWPDQXDO
UHIHUHQFHLQIRUPDWLRQ.

3HAC 021333-001 A 47
'HVFULSWLRQFRQWUROV\VWHP
2.5.1 External axes (Not for IRB 340!)

48 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.1 Introduction

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
,QWURGXFWLRQ

'HILQLWLRQV This chapter chapter contains necessary information for installing the controller to the work-
ing site.

3HAC 021333-001 A 49
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.2.1 Transporting and unpacking, S4Cplus

8QSDFNLQJ

7UDQVSRUWLQJDQGXQSDFNLQJ6&SOXV

*HQHUDO Before starting to unpack and install the robot system, read the safety regulations and other
instructions very carefully. These are found in separate sections in the User’s Guide and Prod-
uct manual.
The installation must be done by qualified installation personnel and should conform to all
national and local codes.
When you unpack the cabinet, check that it was not damaged during transport or while
unpacking.

:HLJKWFRQWUROOHU The table below shows the weights for the controller:
FDELQHW

&RQWUROOHU :HLJKW
S4Cplus controller cabinet M2000 240 kg
Distributed Drive Unit (option) 30 kg

2SHUDWLQJFRQGL The table below shows the allowed operating conditions for the controller:
WLRQVFRQWUROOHU
FDELQHW
3DUDPHWHU 9DOXH
Min. ambient temperature +5°C
Max. ambient temperature (standard) +45°C
Max. ambient temperature (option) +52°C
Max. ambient humidity Max. 95% at constant temperature

6WRUDJHFRQGL The table below shows the allowed storage conditions for the controller:
WLRQVFRQWUROOHU
FDELQHW
3DUDPHWHU 9DOXH
Min. ambient temperature -25°C
Max. ambient temperature +55°C
Max. ambient temperature (less than 24 h) +70°C
Max. ambient humidity Max. 95% at constant temperature

50 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.2.1 Transporting and unpacking, S4Cplus

3URWHFWLRQFODVV The table below shows the protection class of the controller:
FRQWUROOHU

(TXLSPHQW 3URWHFWLRQFODVV
Control cabinet IP 54
Programming unit IP 54
Distributed Drive Unit (option) IP 54

1RWH Additional installations out from the cabinet must be sealed properly in order to pre-
serve the protection class.

3HAC 021333-001 A 51
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.1 Lifting the controller cabinet

2QVLWH,QVWDOODWLRQ

/LIWLQJWKHFRQWUROOHUFDELQHW

/LIWLQJGHYLFH Use the four lifting devices on the cabinet or a fork lift when lifting the controller cabinet
S4Cplus as shown below.
The figure below shows the minimum angle between the lifting straps and the cabinet when
lifting the controller.

B
xx0100000153

A Min. 60°when lifting with straps

B Fork lift

&DXWLRQ
Lift the cabinet level by using all four attachment lugs! Also be aware of the minimum angle!
Otherwise the cabinet may be damaged.

&DELQHWGHOLYHUHG If the controller is delivered without its top cover, a fork lift PXVW be used. Do not use lifting
ZLWKRXWWRSFRYHU devices!

52 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.2 Required installation space, control cabinet

5HTXLUHGLQVWDOODWLRQVSDFHFRQWUROFDELQHW

'LPHQVLRQV The figure below shows the required installation space for the S4CPlus control cabinet:

200 200

800

800 B

820

950
980*

500
70
620
xx0100000156

A Air distance to wall

B Cabinet extension (Option 124)
* Castor wheels (Option 126)

3HAC 021333-001 A 53
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.3 Bolt pattern, control cabinet

%ROWSDWWHUQFRQWUROFDELQHW

'LPHQVLRQV The figure below shows the floor bolt pattern for the S4CPlus control cabinet:

xx0100000157

54 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.4 Installation of external power transformer

,QVWDOODWLRQRIH[WHUQDOSRZHUWUDQVIRUPHU

8VDJH This external power transformer is used for the manipulators IRB 7600, IRB 6600 and IRB
6650, for voltages:
• 200-220 VAC
The external power transformer is also used if the control cabinet is not equipped with a
transformer 400-600 VAC (3HAC021002-001) and for voltages:
• 500-600 VAC
• 400 and 440 VAC, all IRB 7600 manipulators and manipulator IRB 6650 - 125/3.2.

([WHUQDOSRZHU The external power transformer is located outside the controller. The illustration below shows
WUDQVIRUPHU the cable glands and the lifting lugs/locking screws.

xx0100000154

A Cable glands for input and output cables (large gland; input cable, small
gland; output cable)
B Locking screws/lifting lugs

5HTXLUHGHTXLS
PHQW
(TXLSPHQWHWF $UWQR 1RWH
External power transformer unit 3HAC 11668-1
Input cables Rec. 16 mm 2
Output cables Rec. 6 mm 2
Fuse and holder Mains voltage 200 VAC: 63 A
Mains voltage 600 VAC: 25 A

3HAC 021333-001 A 55
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.4 Installation of external power transformer

(TXLSPHQWHWF $UWQR 1RWH

Circuit breaker Configured for the expected cur-
rents.
Standard toolkit 3HAC 15571-1 The contents are defined in section
Standard toolkit!
Other tools and procedures may These procedures include refer-
be required. See references to ences to the tools required.
these procedures in the step-by-
step instructions below.
Circuit Diagram, controller 3HAC 5582-2
Circuit Diagram, external power 3HAC 11668-11
transformer

6DIHW\LQIRUPD Read the safety text below before installation of the external power transformer.
WLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

&RQQHFWLRQV The procedure below details how to connect the external power transformer unit.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 56.
2. Connect the shop mains power supply. Detailed in 6KRSPDLQVSRZHU
VXSSO\ on page 56!
3. Connect the external power transformer input. Detailed in 7UDQVIRUPHULQSXW
on page 57!
4. Connect the external power transformer output. Detailed in 7UDQVIRUPHURXWSXW
on page 57!
5. Connect the controller input. Detailed in &RQWUROOHULQSXW on
page 57!

6KRSPDLQV The procedure below describes what to pay attention to when connecting the Shop mains
SRZHUVXSSO\ power supply.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 56.
2. Make sure the shop supply is fitted with suit- Fuse size specified in the table
able circuit breakers and fuses. 5HTXLUHGHTXLSPHQW on page 55!

56 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.4 Installation of external power transformer

7UDQVIRUPHULQSXW The procedure below details how to connect the Transformer input.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 56.
2. Run a cable from the shop supply outlet Shown in the figure ([WHUQDOSRZHU
through the input cable inlet on the trans- WUDQVIRUPHU on page 55!
former unit.
3. Open the transformer unit by removing the Shown in the figure ([WHUQDOSRZHU
lock screws on top of the unit. WUDQVIRUPHU on page 55!
4. Connect the LQSXW cable earth conductor to
the earth terminal.
5. Connect the three input phases to the long Terminal: X1
terminal.
Make sure the cables are connected to the
terminals marked with the voltage value
corresponding to the voltage supplied.
6. Make sure all terminals are tightened to Tightening torque: approx. 2 Nm
ensure good electric contact.

7UDQVIRUPHURXW The procedure below details how to connect the Transformer output.
SXW

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 56.
2. Run a cable from the transformer unit Shown in the figure ([WHUQDOSRZHU
through the output cable outlet to the robot WUDQVIRUPHU on page 55!
controller.
3. Connect the RXWSXW cable earth conductor to
the transformer unit earth terminal.
4. Connect the three output phases to the out- Terminals: X1.1, X1:2 and X1:3
put terminals.
The terminals are marked with "475" for the
output voltage.
5. Make sure all terminals are tightened to Tightening torque: approx. 2 Nm
ensure good electric contact.

&RQWUROOHULQSXW The procedure below details how to connect the Controller input.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ
on page 56.
2. Remove the left cover plate
under the robot controller
top lid.

3HAC 021333-001 A 57
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.4 Installation of external power transformer

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

3. Route the transformer out-
put cable through the gland
located on the left cabinet
wall.
4. Connect the cable inside
the robot controller (not A
dependent on phase
sequence): B
• Phase 1 to L1
C
• Phase 2 to L2 D
• Phase 3 to L3
• 0 to XT26.N
• Earth to the cabinet xx0100000155

earth connection (C • A: Terminal X26

in the figure to the
• B: Connectors
right). The earth
connection is • C: Earth connection (PE)
marked with a "PE" • D: Cable glands
sticker.
5. Make sure all terminals are Tightening torque: approx. 2 Nm
tightened to ensure good
electric contact.

58 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.5 Installation of Distributed Drive Unit -VW (DDU-VW)

,QVWDOODWLRQRI'LVWULEXWHG'ULYH8QLW9:''89:

*HQHUDO This section gives necessary information when installing the Distributed Drive Unit (DDU):
• Required installation space
• Bolt pattern
• Connection to earth
• Fan cooling
• Cabling
• In case of overheating
For further information, see the Circuit Diagram, included in the Repair Manual, part 2 (art.
no. is specified in section 'RFXPHQW5HIHUHQFHV).

5HTXLUHGLQVWDOOD The external DDU (option) is installed outside the control cabinet. The figure below shows
WLRQVSDFH''8 the required installation space for the DDU.

300 A

A A

xx0200000340

A 50 mm, required free area for the exhaust air

3HAC 021333-001 A 59
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.5 Installation of Distributed Drive Unit -VW (DDU-VW)

%ROWSDWWHUQ''8 Suspend the DDU nearby the control cabinet, using the bolt pattern shown in the figure below.

253
xx0200000374

&RQQHFWLRQWR If the difference of potential between the control system and the DDU is too large or there are
HDUWK suspicions of shorter drops in voltage, the DDU must be grounded. This is done at the con-
nection point GND (see the section &RQQHFWRUVRQWKHGLVWULEXWHGGULYHXQLW''8 on page
66).

)DQFRROLQJ The main power from the control cabinet also feeds two fans in the DDU via an internal
transformer with three input taps.
The transformer wires are connected, under the lid, as
• 0 - 400V for nominal mains input 400V
• 0 - 440V for nominal mains input 440V
• 0 - 480V for nominal mains input 480V

&DEOLQJ Section &RQQHFWLQJWKHPDQLSXODWRUWRWKHFRQWUROFDELQHW6&SOXVFDEOLQJ on page 62 spec-

ifies which cables to use and to which connectors these are to be connected, in order to con-
nect the DDU to either the controller, the manipulator or to the external axis.
If cables other than the ones delivered from ABB/SEROP are used, the Circuit Diagram must
be followed! A motor that is connected to the DDU must be connected to the equipment
grounding (protective bonding) via the frame in the connector XS77/XS78!

,QFDVHRIRYHU Overheating of the DDU may be caused by the following:

KHDWLQJ • A line voltage lower than 480V is used, while the fans are connected as 480V. This
causes a reduced fan cooling. See "Changing the connection of the transformer"
below.
• The fuse, located at the screw terminal, has caused the fans to stop.
• Insufficient airflow. See "Increasing the airflow" below.
• Too heavy drive at too high ambient temperature. See the manual ([WHUQDOD[HV. Art.
no. for the manual is specified in section 'RFXPHQWUHIHUHQFHVin the 3URGXFWPDQXDO
UHIHUHQFHLQIRUPDWLRQ.

60 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.3.5 Installation of Distributed Drive Unit -VW (DDU-VW)

Changing the con- The default connection of the transformer is the nominal mains input 480V. The cooling is,
nection of the however, reduced, when a lower line voltage is used and there may be a risk that the drive
transformer unit is triggered at a high surrounding temperature. Therefore, if the line voltage differs from
480V, it is recommended to switch the default connection over to 440V or 400V instead.
To change the voltage, remove the lid of the DDU and switch the connections on the screw
terminals (see the section &RQQHFWLRQVWRVFUHZWHUPLQDOV on page 74).

Increasing the air- If there appears to be an overheating of the DDU, without suspicion of reduced fan cooling,
flow the airflow may be increased by replacing the two covering plates with vents, see figure
below. This gives four openings instead of the default two.

xx0200000373

A Vent
B Covering plate

3HAC 021333-001 A 61
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.1 Connecting the manipulator to the control cabinet, S4Cplus cabling

(OHFWULFDOFRQQHFWLRQV

6LJQDO3RZHUFDEOHV

&RQQHFWLQJWKHPDQLSXODWRUWRWKHFRQWUROFDELQHW6&SOXVFDEOLQJ

*HQHUDO Connect the manipulator and control cabinet to each other after securing them to the founda-
tion. The lists below specify which cables to be used in each application respectively.
Manipulator cabling is specified in the 3URGXFW0DQXDOfor the manipulator, in the chapter
,QVWDOODWLRQDQGFRPPLVVLRQLQJ. For reference information see 'RFXPHQWUHIHUHQFHV.

&XVWRPHUFDEOHV These cables are QRWincluded in the standard delivery, but are included in the delivery of each
specific option. The cables are QRW ready to plug in, but require connection to terminals inside
the control cabinet as well as keying. These activities are detailed in Customer Connection
Kit.

&RQQHFWLRQSRLQW
&DEOH $UWQR &RQQHFWLRQSRLQWFDELQHW
PDQLSXODWRU
Fieldbus cable, 3HAC 13173-1 XT/XP5.1 R1.CP/CS
CAN, 7 m XT/XP6
XS6
Fieldbus cable, 3HAC 13173-2 XT/XP5.1 R1.CP/CS
CAN, 15 m XT/XP6
XS6
Fieldbus cable, 3HAC 13173-4 XT/XP5.1 R1.CP/CS
CAN, 30 m XT/XP6
XS6
Fieldbus cable, 3HAC 13174-1 XT/XP5.1 R1.CP/CS
Profibus, 7 m XT/XP6
DP/M
Fieldbus cable, 3HAC 13174-2 XT/XP5.1 R1.CP/CS
Profibus, 15 m XT/XP6
DP/M
Fieldbus cable, 3HAC 13174-4 XT/XP5.1 R1.CP/CS
Profibus, 30 m XT/XP6
DP/M
Harness CP/CS, 3HAC 14890-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
CAN, 7 m XS13
Harness CP/CS, 3HAC 14890-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
CAN, 15 m XS13
Harness CP/CS, 3HAC 14890-6 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
CAN, 30 m XS13
Harness CP/CS, 3HAC 15644-4 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
Interbus, 7 m XS13
Harness CP/CS, 3HAC 15644-1 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
Interbus, 15 m XS13

62 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.1 Connecting the manipulator to the control cabinet, S4Cplus cabling

&RQQHFWLRQSRLQW
&DEOH $UWQR &RQQHFWLRQSRLQWFDELQHW
PDQLSXODWRU
Harness CP/CS, 3HAC 15644-5 XT/XP5.1 - XT/XP5.2 - XT/XP6.1 R1.CP/CS
Interbus, 30 m XS13

([WHUQDOD[HV The cables between the DDU (Distributed Drive Unit) and the cabinet are included in the
FDEOHV optional delivery of the DDU.
The cables between the DDU, the external axis, the manipulator etc. are not included in the
delivery, but are ordered as separate options.

&DEOHGHVFULSWLRQ $UWQR
Cable harness DDU 3HAC 15910-1
Harness CP/CS, axes 7, 7 m (RG) 3HAC 14959-4
Harness CP/CS, axes 7, 15 m (RG) 3HAC 14959-1
Harness CP/CS, axes 7, 30 m (RG) 3HAC 14959-5
Harness Servogun, 7 m (SG) 3HAC 15386-4
Harness Servogun, 15 m (SG) 3HAC 15386-1
Harness Servogun, 30 m (SG) 3HAC 15386-5
SMB signals cable, 7 m 3HAC 11898-1
SMB signal cable, 7 m (SG) 3HAC 16425-1
SMB signal cable, 1,5 m (SG+RG) 3HAC 16679-1
SMB signal cable, 7 m (SG+RG/SG) 3HAC 16832-1
SMB signal cable, 15 m (SG+RG/SG) 3HAC 16832-2
SMB signal cable, 30 m (SG+RG/SG) 3HAC 16832-3
SMB signal cable, 7 m (SG/RG+T) 3HAC 12001-1
SMB signal cable, 15 m (SG/RG+T) 3HAC 12001-2
SMB signal cable, 30 m (SG/RG+T) 3HAC 12001-4

Following tables specifies connection points for the cables.

Connection points,
external axes,
power &RQQHFWLRQ
&RQQHFWLRQ
&RQQHFWLRQSRLQW &RQQHFWLRQ SRLQW
$UWQR SRLQW
PDQLSXODWRU SRLQW''8 H[WHUQDO
FDELQHW
D[LV
3HAC 15910-1 XS44 - XP49 -
3HAC 14959-4/1/5 XS13 R1.CP/CS XS77 -
3HAC 15386-4/1/5 - - XS77 (SG)

3HAC 021333-001 A 63
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.1 Connecting the manipulator to the control cabinet, S4Cplus cabling

Connection points,
external axes, sig-
nals &RQQHFWLRQ &RQQHFWLRQ &RQQHFWLRQSRLQW
&RQQHFWLRQ
$UWQR SRLQW SRLQW H[WHUQDOD[LV
SRLQW''8
FDELQHW PDQLSXODWRU 60%ER[
3HAC 11898-1 XS41 - XP49 -
3HAC 16425-1 - R1.FB7 - (SG)
3HAC 16679-1 - R1.FB7 - SMB: FB.M7
3HAC 16832-1/2/3 XS41 - - SMB: SMB.1
3HAC 12001-1/2/4 XS41 - - SMB: SMB.1

64 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.2 Connectors on control cabinet, S4Cplus

&RQQHFWRUVRQFRQWUROFDELQHW6&SOXV

*HQHUDO Section &RQQHFWLQJWKHPDQLSXODWRUWRWKHFRQWUROFDELQHW6&SOXVFDEOLQJ on page 62 spec-

ifies which cables to use and to which connectors these are to be connected, in order to con-
nect the controller to the manipulator.

&RQQHFWLRQVWR All control cabinet connectors are shown in the figure below.
WKHFDELQHW

xx0100000247

* For 6400S/640 and Can Bus

** Option for 66X0 and 7600

3HAC 021333-001 A 65
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.3 Connectors on the distributed drive unit, DDU

&RQQHFWRUVRQWKHGLVWULEXWHGGULYHXQLW''8

*HQHUDO The section &RQQHFWLQJWKHPDQLSXODWRUWRWKHFRQWUROFDELQHW6&SOXVFDEOLQJ on page 62

specifies which cables to use and to which connectors these are to be connected, in order to
connect the DDU (distributed drive unit) to either the controller, the manipulator or to the
external axis.

&RQQHFWLRQVWR The connectors on DDU-VW are shown in the figure below.

WKH''89:

xx0200000372

The connections on the manipulator are located on the rear of the robot base.

&RQQHFWLRQVWR The connectors on DDU-U are shown in the figure below.

WKH''88ORZ
YROWDJH

xx0400000723

A Cover

66 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.4 Connection of mains power to control cabinet, S4Cplus

&RQQHFWLRQRIPDLQVSRZHUWRFRQWUROFDELQHW6&SOXV

*HQHUDO Connect the power supply either inside the cabinet, or to an optional socket on the left-hand
side of the cabinet or the lower section of the front. The cable connector is supplied but not
the cable.
Configure the mains supply cables and fuses in accordance with the rated power and line
voltage, see rating plate on the controller.

&RQQHFWLRQVWR Also see the Circuit Diagram.

WKHPDLQVVZLWFK The instruction below details how to make all the required connections to the mains switch:

xx0100000248

A XT 26
B Protective Earth connection
C Cable gland
D Connector

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

1. Remove the left cover plate under the top lid.
2. Pull the mains cable (outer diam. 10.2 mm) through Shown in the figure above!
the JODQG located on the left cabinet wall.
3. Release the connector from the knob by pushing
the release buttons located on the side of the con-
nector.
4. Connect phase: Shown in the figure above!
• 1 to L1 (Not dependent on phase sequence) NOTE! Max. conductor size
• 2 to L2 is 6 mm2 (AWG 10). Tighten
to a torque of 2.3-2.5 Nm.
• 3 to L3 Retighten after approx. 1
• 0 to XT26.N (line neutral is needed only for week.
option 432)
• and protective earth to the SURWHFWLYHHDUWK
FRQQHFWLRQ

3HAC 021333-001 A 67
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.1.4 Connection of mains power to control cabinet, S4Cplus

6WHS $FWLRQ ,QIR,OOXVWUDWLRQ

5. Snap the breaker on to the knob again and check
that it is fixed properly in the correct position.
6. Tighten the cable gland.
7. Fasten the cover plate.

&RQQHFWLRQ It is possible to connect the mains supply via an industrial Harting connector (DIN 41 640)
WKURXJKDSRZHU or a CEE17 connector. See the figure below:
VRFNHW Cable connectors are supplied (option 132 - 134).

xx0100000162

A DIN connector
B CEE connector (not available for IRB 66X0/7600)

68 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.1 Signal Classes

6LJQDOFRQQHFWLRQV

6LJQDO&ODVVHV

2YHUYLHZ Different rules apply to the different classes when selecting and laying cable. Signals from
different classes must not be mixed.

6LJQDOV • 3RZHU6LJQDOVSupplies external motors and brakes.

• 'LJLWDOVLJQDOV Measuring, control and data signals (digital I/O, safety stops, etc.).
• $QDORJVLJQDOV Measuring and control signals (resolver and analog I/O).
• 'DWDFRPPXQLFDWLRQVLJQDOVField bus connection, RS422, RS 485, SMBUS, drive/
measurement system.

3HAC 021333-001 A 69
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.2 Selecting Cables

6HOHFWLQJ&DEOHV

&RQWUROOHUFDEOHV All cables laid in the controller must be capable of withstanding +70°C.

3RZHU6LJQDO Shielded cable with an area of at least 0.75mm 2 or AWG 18.

Note that any local standards and regulations concerning insulation and area must always be
complied with.

&RQWUROVLJQDOV Shielded cables.

0HDVXULQJVLJ Shielded cable with twisted pair conductors.

QDOV

'DWDFRPPXQLFD Shielded cable with twisted pair conductors.

WLRQVLJQDOV

A specific cable should be used for Gateway (Field bus) connections.

'HYLFH1HWIRUGLV A thin cable according to DeviceNet specification release 2.0, must be used, e.g. ABB article
WULEXWLQJ,2XQLWV no. 3HAB 8277-1. The cable is shielded and has four conductors, two for electronic supply
and two for signal transmission.
The end-to-end network distance varies with data rate and cable thickness, for information
see the table.

'DWDUDWHV N%SV N%SV N%SV

Thick trunk length 500 m 250 m 100 m
(1,640 ft) (820 ft) (328 ft)
Thin trunk length 100 m 100 m 100 m
(328 ft) (328 ft) (328 ft)
Flat trunk cable 380 m 200 m 75 m
(1,250 ft) (656 ft) (246 ft)
Maximum drop length 6m 6m 6m
(20 ft) (20 ft) (20 ft)
Cumulative drop length 156 m 78 m 39 m
(512 ft) (256 ft) (128 ft)

Note that a separate cable for suppling I/O loads is required.

70 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.2 Selecting Cables

$OOHQ%UDGOH\ Cables according to Allen-Bradley specification, e.g. "Blue hose", should be used for connec-
5HPRWH,2 tions between DSQC 350 and the Allen-Bradley PLC bus.

,QWHUEXV6 Cables according to Phoenix specification, e.g. "Green type", should be used for connections
between the DSQC 351 and external Interbus-S bus.

3URILEXV'3 Cables according to Profibus DP specification should be used for connections between the I/
O unit DSQC 352 and the external Profibus DP bus.

(WKHUQHW For Ethernet applications, the following cables are recommended:

• 10 Mbit/s: Shielded twisted pair conductors (10 Base T STP)
• 100 Mbit/s (<10 m): CAT5E, 100 Base T STP
• 100 Mbit/s (10-100 m): CAT6, 100 Base T STP

3HAC 021333-001 A 71
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.3 Coil neutralization

&RLOQHXWUDOL]DWLRQ

([WHUQDOXQLWV External relay coils, solenoids, and other units that will be connected to the controller must
be neutralized. The figure below illustrates how this can be done.

The turn-off time for DC relays increases after neutralization, especially if a diode is con-
nected across the coil. Varistors give shorter turn-off times. Neutralizing the coils lengthens
the life of the switches that control them.

&ODPSLQJZLWKD The diode should be dimensioned for the same current as the relay coil, and a voltage of twice
GLRGH the supply voltage.

xx0100000163

&ODPSLQJZLWKD The varistor should be dimensioned for the same current as the relay coil, and a voltage of
YDULVWRU twice the supply voltage.

xx0100000164

&ODPSLQJZLWKDQ R 100 ohm, 1W C 0.1 - 1 mF.

5&FLUFXLW >500V max. voltage, 125V nominal voltage.

xx0100000165

72 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.4 Connection types

&RQQHFWLRQW\SHV

*HQHUDO I/O, external emergency stops, safety stops, etc. can be supplied on screw connections or as
industrial connectors.

&RQQHFWLRQV

'HVLJQDWLRQ &RQQHFWLRQW\SH
X(T) Screw terminal
XP Pin (male)
XS Sockets (female)

3HAC 021333-001 A 73
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.2.5 Connections to screw terminals

&RQQHFWLRQVWRVFUHZWHUPLQDOV

2YHUYLHZ This section describes how to connect conductors to screw terminals. Detailed information
about connection location and functions will be found in the circuit diagram (Service Man-
ual).

,QVWDOODWLRQ The installation must comply with the IP54 (NEMA 12) protective standard.
 Bend unused conductors backwards and attach them to the cable using a cable tie, or
similar.

To prevent interference, ensure that unused conductors are not connected at the other end of
the cable (antenna effect).
In environments with much interference, disconnected conductors should be grounded (0V)
at both ends.

74 A 3HAC 021333-001
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3.4.2.6 Connections to connectors

&RQQHFWLRQVWRFRQQHFWRUV

/RFDWLRQRIFRQ If ordered, industrial connectors can be found on the left-hand side or front of the control
QHFWRUV cabinet (depending on the customer order). Also see the figure in section "Connectors on
control cabinet"!
The manipulator arm (not IRB 940 Tricept) is equipped with round Burndy/Framatome con-
nectors (customer connector not included).

Connectors, Each industrial connector has accommodation for four rows of 16 conductors with a maxi-
description mum conductor area of 1.5 mm 2 . The pull-relief clamp must be used when connecting the
shield to the case.

0DNLQJWKHFRQ The section below details how to crimp cable connections to pins:
QHFWLRQ  Using a special crimp tool, crimp a pin or socket on to each non-insulated conductor.
When two conductors are connected to the same pin or socket, both of them must be
crimped into the same pin or socket. A maximum of two conductors may be crimped into
the same pin or socket.
 Snap the pin into the connector housing.
 Push the pin into the connector until it locks.
 A special extractor tool must be used when removing pins or sockets from industrial con-
nectors.

3HAC 021333-001 A 75
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.3.1 The MOTORS ON/MOTORS OFF circuit

&XVWRPHUFRQQHFWLRQVRQFRQWUROOHU

7KH027256210272562))FLUFXLW

2XWOLQHGLDJUDP The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS and ES.

A
E
C
B D

G F
H

J
R S T M

N
L
P
xx0100000174

A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
J AS (Automatic mode safeguarded space stop)
K ED (TPU enabling device)
L Manual mode
M Motor
N Automatic mode
P Operating mode selector
R RUN
S EN1
T EN2

76 A 3HAC 021333-001
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3.4.3.1 The MOTORS ON/MOTORS OFF circuit

)XQFWLRQRIWKH The circuit monitors all safety related equipment and switches. If any of the switches are
02725621 opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off.
0272562))FLU As long as the two chains are not identical, the robot will remain in MOTORS OFF mode.
FXLW

&RQQHFWLRQRI The diagram below shows the two-channel safety chain.

VDIHW\FKDLQV The supply from internal 24V (X3/X4:12) and 0 V (X3/X4:7) is displayed. For an external
supply of GS and AS, X3/X4:10,11 is connected to 24V and X3/X4:8,9 is connected to exter-
nal 0V. Connection tables for X1-X4 are given in "External customer connections on panel
X1 - X4".

24V E xt LIM1 K1
X3:12 24V 0V
X1:11 12
X4:12

X3:10 ES1
Opto GS 1
8 is ol.
T PU E n1 & EN K1
11
R un Intern
Opto AS 1
locking K2
9 is ol.
Auto1 Man1
E xternal contactors
X3:3 4 CONT 1
0V
24 V X4:3 4 CONT 2
E xt LIM2
X2:11 12 K2
0V 24 V

ES 2 Drive Unit
X4:10
Opto GS 2
8 is ol. M
T PU E n2 &
11
Opto AS 2
9 is ol.
Auto2 Man2

xx0100000166

7HFKQLFDOGDWDSHUFKDLQ
Limit switch Load: 300 mV
Max. voltage drop: 1 V
External connectors Load: 10 mA
Max. voltage drop: 4 V
GS/AS load at 24 V 25 mA
GS/AS closed "1" >18 V
GS/AS open "0" <5V

3HAC 021333-001 A 77
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3.4.3.1 The MOTORS ON/MOTORS OFF circuit

7HFKQLFDOGDWDSHUFKDLQ
External supply of GS/AS Max. + 35 VDC
Min. - 35 VDC
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals

&RQQHFWLRQRI The diagram below shows the terminals for the emergency circuits.
(6(6RQSDQHO The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For an ext. sup-
XQLW ply, X1:3 / X2:9 is connected to ext. 24V, and X1:9 / X2:3 is connected to ext. 0V (dotted
lines).
A

24V 0V
B C D
X1:4 X1:3
X1:7
X1:10 X1:9 X1:8

X1:1

X1:2
24V

X1:6
E
24V
X1:4
X1:5
G
0V 24V
F
B C D
X2:4 X2:3
X2:7

X2:10 X2:9 X2:8

X2:1

X2:2
24V

X2:6
H
24V
X2:4
X2:5

J
xx0100000191

A Internal
B Ext stop

78 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.3.1 The MOTORS ON/MOTORS OFF circuit

C TPU
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
J Run chain 2 top

7HFKQLFDOGDWD
ES1 and ES2 max output voltage 120 VAC or 48 VDC
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay 24 VDC ±10% between terminals X1:9, 8 and X2:9, 8
respectively.
1RWH In case of interference, the external supply must
be properly filtered.
Rated current per chain 40 mA
Max. potential in relation to the 300 V
cabinet earthing and other signal
groups.
Signal class Control signals

&RQQHFWLRQWR The diagram below shows the connection of terminals for customer use.
02725621
0272562)) A
FRQWDFWRU
B

X3:2
1
X4:2
1

xx0100000193

A K1 (Motor on/off 1)
B K1 (Motor on/off 2)

7HFKQLFDOGDWD
Max. voltage 48 VDC
Max. current 4A

3HAC 021333-001 A 79
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.3.1 The MOTORS ON/MOTORS OFF circuit

7HFKQLFDOGDWD
Max. potential in relation to the 300 V
cabinet earthing and other signal
groups.
Signal class Control signals

&RQQHFWLRQWR The illustration below shows the connection of terminals for customer use.
RSHUDWLQJPRGH
VHOHFWRU

xx0100000197

A Mode selector

External manual FS (Full Speed) 100% is an option.

For information on where the connector S1.1.X1 is placed in the control cabinet, see illustra-
tion in section &RQQHFWLRQVWRWKHFDELQHW on page 65. The connector is found in the cable
duct.

7HFKQLFDOGDWD
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals

80 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.3.1 The MOTORS ON/MOTORS OFF circuit

&RQQHFWLRQWR The diagram below shows the connection of terminals for customer use.
EUDNHFRQWDFWRU

xx0100000199

A K3 (Brake)

7HFKQLFDOGDWD
Max. voltage 48 VDC
Max. current 4A
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Signal class Control signals

3HAC 021333-001 A 81
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.3.2 External customer connections on panel X1 - X4

([WHUQDOFXVWRPHUFRQQHFWLRQVRQSDQHO;;

2XWOLQHGLDJUDP The diagram shows the customer connections X1 - X4 located on the panel unit.

A
A

xx0100000205

A pin 1

&RQQHFWLRQRI; The table below shows the signal descriptions for X1.
SROHW\SH The signal names refer to the Circuit Diagram.
3KRHQL[&20
%,&21FRQQHFWRU
6LJQDO 7HUPLQDOQR &RPPHQW
ES1 out: A 1 Emergency stop out chain 1
ES1 out: B 2 Emergency stop out chain 1
ES1 top 3 Top of emergency stop chain 1
24 V panel 4 + 24 V emergency stop chain 1 and run chain 1
Run ch1 top 5 Top of run chain 1
ES1 internal 6 Internal signal from emergency stop relay chain 1
Sep. ES1: A 7 Separated emergency stop chain 1
Sep. ES1: B 8 Separated emergency stop chain 1
ES1 bottom 9 Bottom of emergency stop chain 1
0V 10 0 V emergency stop chain 1
Ext. LIM1: A 11 External limit switch chain 1

82 A 3HAC 021333-001
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3.4.3.2 External customer connections on panel X1 - X4

6LJQDO 7HUPLQDOQR &RPPHQW

Ext. LIM1: B 12 External limit switch chain 1

&RQQHFWLRQRI; The table below shows the signal descriptions for X2.
SROHW\SH The signal names refer to the Circuit Diagram.
3KRHQL[&20
%,&21FRQQHFWRU
6LJQDO 7HUPLQDOQR &RPPHQW
ES2 out: A 1 Emergency stop out chain 2
ES2 out: B 2 Emergency stop out chain 2
ES2 top 3 Top of emergency stop chain 2
0V 4 0 V emergency stop chain 2
Run ch2 top 5 Top of run chain 2
ES2 internal 6 Internal signal from emergency stop relay chain 2
Sep. ES2: A 7 Separated emergency stop chain 2
Sep. ES2: B 8 Separated emergency stop chain 2
ES2 bottom 9 Bottom of emergency stop chain 2
24 V panel 10 + 24 V emergency stop chain 1 and run chain 2
Ext. LIM2: A 11 External limit switch chain 2
Ext. LIM2: B 12 External limit switch chain 2

&RQQHFWLRQRI; The table below shows the signal descriptions for X3.
SROHW\SH The signal names refer to the Circuit Diagram.
3KRHQL[&20
%,&21FRQQHFWRU
6LJQDO 7HUPLQDOQR &RPPHQW
Ext. MON 1: A 1 Motor contactor 1
Ext. MON 1: B 2 Motor contactor 1
0V 3 External contactor 1 0 V
CONT1 4 External contactor 1
5 No connection
6 No connection
0V 7 0 V to auto stop (AS) and general stop (GS)
GS1- 8 General stop minus chain 1
AS1- 9 Auto stop minus chain 1
GS1+ 10 General stop plus chain 1
AS1+ 11 Auto stop plus chain 1
24 V panel 12 24 V to auto stop and general stop

3HAC 021333-001 A 83
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3.4.3.2 External customer connections on panel X1 - X4

&RQQHFWLRQRI; The table below shows the signal descriptions for X4.
SROHW\SH The signal names refer to the Circuit Diagram.
3KRHQL[&20
%,&21FRQQHFWRU
6LJQDO 7HUPLQDOQR &RPPHQW
Ext. MON 2: A 1 Motor contactor 2
Ext. MON 2: B 2 Motor contactor 2
24 V panel 3 External contactor 2 24 V
CONT2 4 External contactor 2
Ext. BRAKE A 5 Contactor for external brake
Ext. BRAKE B 6 Contactor for external brake
0V 7 0 V to auto stop (AS) and general stop (GS)
GS2- 8 General stop minus chain 2
AS2- 9 Auto stop minus chain 2
GS2+ 10 General stop plus chain 2
AS2+ 11 Auto stop plus chain 2
24 V panel 12 24 V to auto stop and general stop

84 A 3HAC 021333-001
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3.4.3.3 Connection of external safety relay

&RQQHFWLRQRIH[WHUQDOVDIHW\UHOD\

'HVFULSWLRQ The motor contactors K1 and K2 in the controller can operate with external equipment if
external relays are used.
The figure below shows two examples of how to connect the external safety relays:

&RQQHFWLRQ
H[DPSOHV C D

E
AS GS AS GS
F F
G
E

H
J

xx0100000246

A Panel unit
B Relays with positive action
C Robot 1
D Robot 2
E External supply
F ES (emergency stop) out
G Safety relay
H To other equipment
J Safety gate
K Cell ES (emergency stop)

3HAC 021333-001 A 85
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.4.1 External 24V supply

6XSSOLHV

([WHUQDO9VXSSO\

:KHQLVDQH[WHU An external supply is recommended to make use of the advantages offered by the galvanic
QDOVXSSO\UHFRP insulation on the I/O units or on the panel unit.
PHQGHG" An external supply PXVW be used in the following cases:
• When the internal supply is insufficient.
• When the emergency stop circuits must be independent of whether or not the robot
has power on.

1RWH
In case of interference, the external supply must be properly filtered!

+RZWRFRQQHFW The external supply neutral wire must be connected to the chassis such that the maximum
WKHH[WHUQDOVXS permitted potential difference in the chassis ground is not exceeded. For example, a neutral
SO\ wire can be connected to the chassis ground of the controller, or some other common ground-
ing point.

7HFKQLFDOGDWD

Potential difference to chassis ground Max. 60 V continuously

Max. 500 V during 1 minute
Permitted supply voltage I/O units 19 VDC - 35 VDC incl. ripple
Panel unit 20.6 VDC - 30 VDC incl. ripple

86 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.4.2 24V I/O supply

9,2VXSSO\

*HQHUDO The 24V I/O is not galvanically separated from the rest of the controller voltages.

9'&VXSSO\IRU
LQWHUQDODQG
H[WHUQDOXVH Voltage 24.0 - 26.4V
Ripple Max. 0.2V
Permitted customer load Max. 7,5A
Current limit 13,5 ~0A.

9'&VXSSO\ 24V I/O available for customer connections at XT 31 is shown in the figure in "Connections
DYDLODEOHDW;7 to screw terminals".

XT.31.2 24 V (through a 2 A fuse)

XT.31.1 for own fuses
XT.31.4 0 V (connected to cabinet structure)

3HAC 021333-001 A 87
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.4.3 115/230 VAC supply

9$&VXSSO\

*HQHUDO This voltage is used in the robot for supplying optional service outlets. The AC supply is not
galvanically separated from the rest of the controller voltages.

9$&VXS
SO\IRULQWHUQDO
DQGH[WHUQDOXVH Voltage 115 VAC or 230 VAC
Permitted customer load Max. 500 VA
Fuse size, 115 V 6.3 A
Fuse size, 230 V 3.15 A

9$&VXS 115 VAC/230 VAC available for customer connections at XT 21 is shown in the figure in
SO\DYDLODEOHDW;7 "Connection to screw terminals".


XT.21.1-5 230 VAC

XT.21.6-8 115 VAC
XT.21.9-13 N (connected to cabinet structure)

88 A 3HAC 021333-001
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3.4.5.1 Connection of the DeviceNet bus

%XVHV

&RQQHFWLRQRIWKH'HYLFH1HWEXV

,OOXVWUDWLRQ The illustration below shows an example of how to connect the DeviceNet bus:

xx0100000241

3HAC 021333-001 A 89
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.1 Connection of the DeviceNet bus

A Base connector unit

B DeviceNet bus
C Control cabinet
D I/O
E Termination of last unit
F 120 ohm, 1%, 0.25 W metal film resistor; a termination resistor
G See figure in section &$1 on page 91 below!

Following table describes the connections to the DeviceNet connector.

6LJQDOQDPH ,2SLQ :LUHFRORU )XQFWLRQ

OV_CAN 1 black DeviceNet network power, 0V
CAN_L 2 blue DeviceNet communication bus terminal
drain 3 bare Network cable shield
CAN_H 4 white DeviceNet communication bus terminal
24V_I/O 5 red DeviceNet network power, 24V DC

&$1 Used for internal I/O unit mounted inside the cabinet. No terminating resistor is fitted on
CAN 1.1 regardless of whether any I/O units are used or not. CAN 1.1 is connected to socket
X15 on the Base connector unit (see ,OOXVWUDWLRQ).

&$1 If CAN 1.2 is not used, a terminating resistor must be connected to the X6 socket (see below
for exceptional case!).
If CAN 1.2 is used, the terminating resistor should be moved to the last I/O unit on the CAN
1.2 chain.

If CAN 1.2, for example, is not connected at the end of any DeviceNet chain but somewhere
between the end points of the chain, then no terminating resistor should be mounted in CAN
1.3. This is in accordance with the basic rule, i.e. the DeviceNet chain should be terminated
at both end points.

&$1 If CAN 1.3 is unused, a terminating resistor must be connected to the X7 socket.
If CAN 1.3 is used, the terminating resistor should be moved to the last I/O unit on the CAN
1.3 chain.

If CAN 1.2, for example, is not connected at the end of any DeviceNet chain but somewhere
between the end points of the chain, then no terminating resistor should be mounted in CAN
1.3. This is in accordance with the basic rule, i.e. the DeviceNet chain should be terminated
at both end points.

90 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.1 Connection of the DeviceNet bus

7HUPLQDWLRQ The DeviceNet chain must be terminated with terminating resistors at each end!
UHVLVWRUVLQ If CAN 1.2, for example, is not connected at the end of any DeviceNet chain but somewhere
'HYLFH1HWEXV between the end points of the chain, then no terminating resistor should be mounted in CAN
1.3.

&$1 The illustration below shows an example of how to connect the CAN 2 bus:

xx0100000242

A Controller
B Base connector unit
C See figure in section ,OOXVWUDWLRQ on page 89 above!
D I/O
E Termination of last unit; 120 ohm, 1%, 0.25 W metal film resistor

The illustration below shows DeviceNet connections on base connector unit:

xx0100000243

3HAC 021333-001 A 91
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.1 Connection of the DeviceNet bus

A X6 CAN 1.2 (external I/O)

B X7 CAN 1.3 (external I/O)
C X8 CAN 2 (external I/O)
D X15 CAN 1.1 (internal I/O)

&RQQHFWRU; Connector X5 is a DeviceNet connector.

xx0100000244

The table below describes the signals for connector X5.

6LJQDOQDPH 3LQ 'HVFULSWLRQ

V- OV 1 Supply voltage GND
CAN_L 2 DeviceNet signal low
DRAIN 3 Shield
CAN_H 4 DeviceNet signal high
V+ 5 Supply voltage 24 VDC
GND 6 Logic GND
MAC ID 0 7 Board ID bit 0 (LSB)
MAC ID 1 8 Board ID bit 1
MAC ID 2 9 Board ID bit 2
MAC ID 3 10 Board ID bit 3
MAC ID 4 11 Board ID bit 4
MAC ID 5 12 Board ID bit 5 (MSB)

6HWWLQJ'HYLFH1HW Each I/O unit is given a unique address (ID). The connector contains address´pins and can be
EXV,' keyed as shown in the figure below. When all terminals are unconnected the highest address
is obtained, i.e. 63. When all terminals are connected to 0V, the address would be 0 (which
will cause an error since address 0 is used by the Panel unit).

To obtain address 10: Cut address pins 2 and 8 (see figure below!)
To obtain address 25: Cut address pins 1, 8 and 16.

92 A 3HAC 021333-001
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3.4.5.1 Connection of the DeviceNet bus

(0 V )
1 2 3 4 5 6 7 8 9 1 0 11 1 2

A
B
C

1 4 16
2 8 32
xx0100000245

A Connector X5
B Address pins
C Address key

7KHIXQFWLRQVRID The physical restrictions within the DeviceNet specification could be bent with help by a
UHSHDWHU repeater.
The functions of a repeater are:
• to amplify the communication signals
• to isolate different segments of the network from each other by making several physi-
cally isolated networks to communicate together as one DeviceNet network, i.e.
addresses could not be duplicated.
A repeater does not consume a DeviceNet address and is invisible to other devices on the
network. Each segment of the DeviceNet network should be terminated separately.

1RWH
Do not create a ring. This would cause the repeater to repeat itself, and result in an overload
in the network.

3HAC 021333-001 A 93
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.1 Connection of the DeviceNet bus

,OOXVWUDWLRQV Following illustrations show examples of applications that use a repeater.

UHSHDWHU The figure below illustrates a repeater used for extending the length of a trunk line.

en0400000724

Control Controller cabinet

TR Terminating resistor
PS Power supply

Following figure illustrates a repeater used for extending the length of a drop line.

en0400000725

Control Ccontroller cabinet

TR Terminating resistor
PS Power supply

By using a repeater in the ways shown above, disturbances (such as ESD/EFT) can be
avoided, which may otherwise propagate to other parts of the network.
Repeaters are also used for following purposes:
• To isolate noisy segments.
• When using several power supplies a repeater could be used to isolate the supplies
from each other to avoid voltage potential differences and ground currents.

94 A 3HAC 021333-001
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3.4.5.2 DeviceNet Bus status LED description

'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ

*HQHUDO Each of the units connected to the DeviceNet Bus includes two or four LED indicators which
indicate the condition of the unit and the function of the network communication.

/('V The LEDs found on the units connected may be divided into two categories

Common LEDs The following LEDs can be found on all units:

• MS - Module status
• NS - Network status

Specific LEDs Certain units also include the following LEDs:

• DeviceNet Tx - DeviceNet network transmit
• DeviceNet Rx - DeviceNet network receive

060RGXOHVWD This bicolor (green/red) LED indicates the status of the devices. It indicates whether or not
WXV the device has power and is operating properly. The LED is controlled by software. The table
below shows the different states of the MS LED.

/('FRORU 'HVFULSWLRQ 5HPHG\&DXVH

Off No power applied to the device. Check power supply.
Green Device is operating in a normal condi- If no light, check other LED
tion. modes.
Flashing green Device needs commissioning due to Check system parameters.
missing, incomplete or incorrect config- Check messages.
uration. The device may be in the
Stand-by state.
Flashing red Recoverable minor fault. Check messages.
Red The device has an unrecoverable fault. Device may need replacing.
Flashing green/ The device is running self test. If flashing for more than a few
red seconds, check hardware.

161HWZRUNVWD This bicolor (green/red) LED indicates the status of the communication link. The LED is
WXV controlled by software. The table below shows the different states of the NS LED.

/('FRORU 'HVFULSWLRQ 5HPHG\&DXVH

Off Device has no power or is not on-line. Check status of MS LED.
The device has not completed the Check power to affected module.
Dup_MAC_ID test yet.

3HAC 021333-001 A 95
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.2 DeviceNet Bus status LED description

/('FRORU 'HVFULSWLRQ 5HPHG\&DXVH

Green The device is on-line and has connec- If no light, check other LED
tion in the established state. modes.
For a group 2 device only: the device is
allocated to a master.
For a UCMM capable device: the
device has one or more established
connections.
Flashing green Device is on-line, but has no connec- Check that other nodes in the
tions in the established state. network are operative.
The device has passed the Check parameter to see whether
Dup_MAC_ID test, is on-line, but has module has correct ID.
no established connections to other
nodes.
For a group 2 device only: the device is
not allocated to a master.
For a UCMM capable device: the
device has no established connections.
Flashing red One or more I/O connections are in the Check system messages.
Time-Out state.
Red Failed communication device. The Check system messages and
device has detected an error rendering parameters.
it incapable of communicating on the
network.
(Duplicate MAC_ID, or Bus-off).

'HYLFH1HW7[ The table below shows the different states of the DeviceNet Tx LED.
'HYLFH1HWQHW
ZRUNWUDQVPLW
/('FRORU 'HVFULSWLRQ 5HPHG\&DXVH
Green Physically connected to the DeviceNet If no light when transmission is
Tx line. Flashes when the CPU is expected, check error messages.
receiving data on the DeviceNet-bus. Check system boards in rack.

'HYLFH1HW5[ The table below shows the different states of the DeviceNet Rx LED.
'HYLFH1HWQHW
ZRUNUHFHLYH
/('FRORU 'HVFULSWLRQ 5HPHG\&DXVH
Green Physically connected to the DeviceNet If no light, check network and
Rx line. Flashes when the CPU is connections.
transmitting data on the DeviceNet-
bus.

96 A 3HAC 021333-001
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3.4.5.3 RIO, remote I/O for Allen-Bradley PLC DSQC 350

5,2UHPRWH,2IRU$OOHQ%UDGOH\3/&'64&

*HQHUDO The unit handles communication between the robot system and the Allen Bradley system.

&RPPXQLFDWLRQ The robot may only communicate with the Allen-Bradley system, or be used in combination
FRQFHSW$OOHQ with the I/O system in the robot. For example, the inputs to the robot may come from the
%UDGOH\ Allen-Bradley system while the outputs from the external equipment of the robot control go
via general I/O addresses. In this case the Allen-Bradley system only reads the outputs as
status signals.

'HILQLWLRQV$OOHQ The Allen-Bradley system can communicate with up to 64 external systems. Each of these
%UDGOH\ systems is called a Rack and is given a Rack Address 0-63. Generally, each robot connected
to the Allen-Bradley system will occupy one rack.
Each rack is divided into four sections called Quarters. Each quarter provides 32 inputs and
32 outputs, and a rack will subsequently provide 128 inputs and 128 outputs. A rack may also
be shared by 2, 3 or 5 robots. Each of these robots will then have the same rack address, but
different starting quarters must be specified.

,OOXVWUDWLRQ The illustration below shows a block diagram of the Allen-Bradley system, where Robot 1
$OOHQ%UDGOH\ uses a full rack while robot 2 and robot 3 share one rack. The rack address, starting quarter
V\VWHP and other required parameters such as baud rate, LED status etc. are entered in the configu-
ration parameters.

Allen Bradley
control s ys tem

R obot 1 - 128 in / 128 out R obot 2 - 64 in / 64 out Other s ys tems

Quarter 1 Quarter 1 64 in / 64 out Quarter 1

Quarter 2 128 in / 128 out Quarter 2 Quarter 2

Quarter 3 R ack ID 13 (example) Quarter 3

R ack s ize 2
Quarter 4 S tarting quarter 1 Quarter 4

R ack ID 12 (example)
R ack s ize 4 R obot 3 - 64 in / 64 out
S tarting quarter 1 64 in / 64 out
Quarter 3

Quarter 4

R ack ID 13 (example)
R ack s ize 2
S tarting quarter 3
en0100000255

7HFKQLFDOGDWD
'64&
No. of digital inputs Unit is programmable for 32, 64, 96 or 128 digital inputs
No. of digital outputs Unit is programmable for 32, 64, 96 or 128 digital outputs

Also see the Allen-Bradley RIO specification.

3HAC 021333-001 A 97
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.3 RIO, remote I/O for Allen-Bradley PLC DSQC 350

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals. Also see
WLRQ Circuit Diagram.

&RQQHFWLRQ The RIO-unit should be connected to an Allen-Bradley PLC using a screened, two conductor
cable.

/D\RXW'64& The figure below shows the layout of the DSQC 350 board:


X5
X9

X8
X3
DSQC 350 ABB Flexible Automation

xx0100000226

X3 Not used
X5 DeviceNet and ID connector
X8 RIO in
X9 RION out

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;

5 1
xx0100000221

The table below shows the connections to connector X8:

6LJQDOQDPH ;SLQ )XQFWLRQ

LINE1 (blue) 1 Remote I/O in
LINE2 (clear) 2 Remote I/O in
Shield 3 Remote I/O in
Cabinet ground 4 Remote I/O in

98 A 3HAC 021333-001
 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.3 RIO, remote I/O for Allen-Bradley PLC DSQC 350

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;

5 1
xx0100000221

The table below shows the connections to connector X9:

6LJQDOQDPH ;SLQ )XQFWLRQ

Blue 1 Remote I/O out
Clear 2 Remote I/O out
Shield 3 Remote I/O out
Cabinet ground 4 Remote I/O out

7HUPLQDWLRQ When the robot is last in a RIO loop, the loop must be terminated with a termination resistor
according to Allen-Bradley’s specification.

:DUUDQW\ This product incorporates a communications link which is licensed under patents and propri-
etary technology of the Allen-Bradley Company, Inc. The Allen-Bradley Company, Inc. does
not warrant or support this product. All warranty and support services for this product are the
responsibility of and provided by ABB Flexible Automation.

%XVVWDWXV/('V The table below shows the significance of the LEDs on the board. For location of the LEDs
see /D\RXW'64& on page 98.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

POWER-24 VDC Green Indicates that a supply voltage is present, and has a
level above 12 VDC.
If there is no light, check that voltage is present on
power unit and in power connector. If not, check cables
and connectors.
If power is applied to the unit but it does not work,
replace the unit.
NS/MS Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
CAN Tx/CAN Rx Yellow See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
NAC STATUS Green Steady green indicates RIO link in operation.
If there is no light, check network, cables and connec-
tions. Also check that PLC is operational.
Flashing green indicates that communication is estab-
lished, but the INIT_COMPLETE bit is not set in NA
chip, or configuration, rack size etc. does not match
configuration set in PLC.
If LED keeps flashing continuously, check setup.

3HAC 021333-001 A 99
,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.4 1 Interbus-S, slave DSQC 351

,QWHUEXV6VODYH'64&

*HQHUDO The unit can be operated as a slave for an Interbus-S system.

6XSSO\ The Interbus-S slave must be fed externally to avoid shutting down the Interbus-S net if a
robot cell is switched off. The 24V power supply must be fed from outside the control cabinet
and be connected to pin 2 on the Phoenix connector located on the Interbus-S card’s front
panel marked 24V.

7HFKQLFDOGDWD See the Interbus-S specification.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

8QLW,' The unit ID to be entered in the Interbus-S master is 3. The length code depends on the
selected data. Width between 1 and 4.

/D\RXW'64& The figure below shows the layout of the DSQC 351 board:


X 20 X 21

X5 X3

xx0100000225

X3 Power connector
X5 DeviceNet connector
X20 Interbus-S, input
X21 Interbus-S, output

100 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.4 1 Interbus-S, slave DSQC 351

&RPPXQLFDWLRQ The Interbus-S system is able to communicate with a number of external devices, depending
FRQFHSW on the number of process words occupied by each unit. The robot may be equipped with one
or two DSQC 351. The Interbus-S inputs and outputs are accessible in the robot as general
inputs and outputs.
For application data, refer to Interbus-S, International Standard, DIN 19258.
An outline diagram of the communication concept is shown below:

xx0100000224

A Master PLC
B Robot 1, word 1:3
C Robot 1, word 4:7
D Robot 2, word 8:11
E 128 inputs/128 outputs
F 64 inputs/64 outputs

7HUPLQDWLRQOLQN A link is connected between pins 5 and 9 in the plug on the interconnection cable connected
to the OUT connector of each unit. The link informs the Interbus-S unit that more units are
connected further out in the chain. (The last unit in the chain does not have a cable connected
and therefore no link).

&RQQHFWLRQV; See DeviceNet Connectors.

'HYLFH1HWFRQ
QHFWRUV

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;
,QWHUEXV6,1
5
6

9
1

xx0100000220

The table below shows the connections to connector X20, Interbus-S IN:

6LJQDOQDPH ;SLQ )XQFWLRQ

TPDO1 1 Communication line TPDO1
TPDI1 2 Communication line TPDI1

3HAC 021333-001 A 101

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.4 1 Interbus-S, slave DSQC 351

6LJQDOQDPH ;SLQ )XQFWLRQ

GND 3 Ground connection
NC 4 Not connected
NC 5 Not connected
TPDO1-N 6 Communication line TPDO1-N
TPDI1-N 7 Communication line TPDI1-N
NC 8 Not connected
NC 9 Not connected

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;
,QWHUEXV6287
5
6

9
1
xx0100000220

The table below shows the connections to connector X21, Interbus-S OUT:

6LJQDOQDPH ;SLQ )XQFWLRQ

TPDO2 1 Communication line TPDO2
TPDI2 2 Communication line TPDI2
GND 3 Ground connection
NC 4 Not connected
+5V 5 + 5 VDC
TPDO2-N 6 Communication line TPDO2-N
TPDI2-N 7 Communication line TPDI2-N
NC 8 Not connected
RBST 9 Synchronization

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;

5 1
xx0100000221

102 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.4 1 Interbus-S, slave DSQC 351

The table below shows the connections to connector X3:

6LJQDOQDPH ;SLQ )XQFWLRQ

0 VDC 1 External supply of Interbus-S
NC 2 Not connected
GND 3 Ground connection
NC 4 Not connected
+ 24 VDC 5 + 24 VDC

%XVVWDWXV/('V The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.
The figure and table below show the location and significance of the LEDs on the board.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

POWER-24 VDC Green Indicates that a supply voltage is present, and has a level
above 12 VDC.
NS/MS Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
CAN Tx/CAN Rx Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
POWER- 5 VDC Green Lit when both 5 VDC supplies are within limits, and no
reset is active.
RBDA Red Lit when this Interbus-S station is last in the Interbus-S
network.
If it is not (which is required), check parameter setup.
BA Green Lit when Interbus-S is active.
If there is no light, check network, nodes and connec-
tions.
RC Green Lit when Interbus-S communication runs without errors.

3HAC 021333-001 A 103

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.5 Profibus-DP, slave DSQC 352

3URILEXV'3VODYH'64&

*HQHUDO The unit can be operated as a slave for a Profibus-DP system.

6XSSO\ The Profibus does not need any external power supply. All the robot cells are connected to
the trunk cable through a special D-sub connector which works as a very short drop cable.
Because of this the profibus will work correctly even if a robot cell is turned off.

7HFKQLFDOGDWD Also see the Profibus-DP specification, International Standard DIN E 19245, part 3.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: I/O Signals. Also see the
WLRQ Circuit diagram.

/D\RXW'64& The figure below shows the layout of the DSQC 352 board:


X20

X5 X3

xx0100000223

X3 Power connector
X5 DeviceNet connector
X20 Profibus connection

104 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.5 Profibus-DP, slave DSQC 352

&RPPXQLFDWLRQ The Profibus-DP system is able to communicate with a number of external devices, depend-
FRQFHSW ing on the number of process words occupied by each unit. The robot may be equipped with
one or two DSQC 352. The Profibus-DP inputs and outputs are accessible in the robot as
general inputs and outputs.
An outline diagram of the communication concept is shown below:

xx0100000222

A Master PLC
B Robot 1, word 1:8
C Robot 1, word 9:16
D Robot 2, word 17:24
E 256 inputs/256 outputs
F 128 inputs/128 outputs

7HUPLQDWLRQ The Profibus cable must be terminated in both ends.

&RQQHFWLRQV; See "Device Net Connectors".

'HYLFH1HWFRQ
QHFWRUV

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;
3URILEXV'3
5
6

9
1
xx0100000220

The table below shows the connections to connector X20, Interbus-S IN:

6LJQDOQDPH ;SLQ )XQFWLRQ

Shield 1 Cable screen
NC 2 Not connected
RxD/TxD-P 3 Receive/Transmit data P
Control-P 4
GND 5 Ground

3HAC 021333-001 A 105

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.5.5 Profibus-DP, slave DSQC 352

6LJQDOQDPH ;SLQ )XQFWLRQ

+5 VDC 6
NC 7 Not connected
RxD/TxD-N 8 Receive/Transmit data N
NC 9 Not connected

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRU;

5 1
xx0100000221

The table below shows the connections to connector X3:

6LJQDOQDPH ;SLQ )XQFWLRQ

0 VDC 1 External supply of Profibus-DP
NC 2 Not connected
GND 3 Ground connection
NC 4 Not connected
+ 24 VDC 5 External supply of Profibus-DP

%XVVWDWXV/('V The figure and table below show the location and significance of the LEDs on the board.
The designations refer to LEDs shown in the figure in section "Layout, DSQC 352" above.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

Profibus active Green Lit when the node is communicating with the master.
If there is no light, check system messages in robot and
in Profibus net.
NS/MS Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
CAN Tx/CAN Rx Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
POWER, 24 VDC Green Indicates that a supply voltage is present, and has a
level above 12 VDC.
If there is no light, check that voltage is present in the
power unit and in the power connector. If not, check
cables and connectors.
If power is applied to the unit but it does not work,
replace the unit.

106 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.1 Distributed I/O units

,2XQLWV

'LVWULEXWHG,2XQLWV

*HQHUDO Up to 20 units can be connected to the same controller but only four of these can be installed
inside the controller. Normally a distributed I/O unit is placed outside the controller.

&RQQHFWLRQ The maximum total length of the distributed I/O cable is 100 m (from one end of the chain to
the other end).
The controller can be one of the end points or be placed somewhere in the middle of the chain.

3DUDPHWHUVHWXS For setup parameters, see User’s Guide, section System Parameters, Topic: I/O Signals.

3HAC 021333-001 A 107

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.2 Distributed I/O, digital sensors

'LVWULEXWHG,2GLJLWDOVHQVRUV

*HQHUDO Digital sensors are connected to one optional digital unit.

7HFKQLFDOGDWD The technical data, such as number and type of input and output, are specified in the Control-
ler Installation Manual, chapter I/O units.

$OORZHGW\SHVRI The table below shows the allowed types of digital sensors to be used, and their signal levels
GLJLWDOVHQVRUV respectively:

Sensor type Logical status

Digital one bit sensor High, "1"
Low, "0"
Digital two bit sensor High, "01"
No signal, "00"
Low, "10"
Error status, "11" (stop program running)

108 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.3 Distributed I/O, digital I/O DSQC 328 (option)

'LVWULEXWHG,2GLJLWDO,2'64&RSWLRQ

*HQHUDO The digital I/O unit handles digital communication between the robot system and any external
systems.

7HFKQLFDOGDWD

No. of inputs 16 (divided into two groups of 8, galvanically isolated from each other)
No. of outputs 16 (divided into two groups of 8, galvanically isolated from each other)
Supply voltage 24 VDC
Supply source 24 V I/O or separate external supply

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD For setup parameters, see Users Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

/D\RXW'64& The figure below show the layout of the DSQC328 board:


xx0100000240

A Status LEDs

&RQQHFWLRQV If supervision of the supply voltage is required, a bridge connection can be made to an
FRQQHFWRU; optional digital input. The supervision instruction must be written in the RAPID program.
This is described in the User’s Guide.
The table below shows the connections to connector X1:

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated output Out ch 1 1
Optically isolated output Out ch 2 2
Optically isolated output Out ch 3 3

3HAC 021333-001 A 109

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.3 Distributed I/O, digital I/O DSQC 328 (option)

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated output Out ch 4 4
Optically isolated output Out ch 5 5
Optically isolated output Out ch 6 6
Optically isolated output Out ch 7 7
Optically isolated output Out ch 8 8
Optically isolated output 0 V for outputs 1-8 9
Optically isolated output 24 V for outputs 1-8 10

&RQQHFWLRQV If supervision of the supply voltage is required, a bridge connection can be made to an
FRQQHFWRU; optional digital input. The supervision instruction must be written in the RAPID program.
This is described in the User’s Guide.
The table below shows the connections to connector X2:

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated output Out ch 9 1
Optically isolated output Out ch 10 2
Optically isolated output Out ch 11 3
Optically isolated output Out ch 12 4
Optically isolated output Out ch 13 5
Optically isolated output Out ch 14 6
Optically isolated output Out ch 15 7
Optically isolated output Out ch 16 8
Optically isolated output 0 V for outputs 9-16 9
Optically isolated output 24 V for outputs 9-16 10

&RQQHFWLRQV The table below shows the connections to connector X3:

FRQQHFWRU;

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated input In ch 1 1
Optically isolated input In ch 2 2
Optically isolated input In ch 3 3
Optically isolated input In ch 4 4
Optically isolated input In ch 5 5
Optically isolated input In ch 6 6
Optically isolated input In ch 7 7
Optically isolated input In ch 8 8
Optically isolated input 0 V for inputs 1-8 9
Optically isolated input Not used 10

110 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.3 Distributed I/O, digital I/O DSQC 328 (option)

The input current is 5.5 mA (at 24V) on the digital inputs. A grounded capacitor, to prevent
disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ohm) may
be used.

&RQQHFWLRQV The table below shows the connections to connector X4:

FRQQHFWRU;

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated input In ch 9 1
Optically isolated input In ch 10 2
Optically isolated input In ch 11 3
Optically isolated input In ch 12 4
Optically isolated input In ch 13 5
Optically isolated input In ch 14 6
Optically isolated input In ch 15 7
Optically isolated input In ch 16 8
Optically isolated input 0 V for inputs 9-16 9
Optically isolated input Not used 10

The input current is 5.5 mA (at 24V) on the digital inputs. A grounded capacitor, to prevent
disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ohm) may
be used.

3HAC 021333-001 A 111

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.4 AD Combi I/O, DSQC 327 (optional)

$'&RPEL,2'64&RSWLRQDO

*HQHUDO The digital I/O unit handles digital and analog communication between the robot system and
any external systems.

7HFKQLFDOGDWD

No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from
each other)
No. of digital outputs 16 (divided into two groups of 8, galvanically isolated from
each other)
No. of analog outputs 2 (galvanically isolated from the controller electronics)
Supply voltage 24 VDC
Supply source, digital I/O 24 V I/O or separate external supply
Supply source, analog I/O 24 V_CAN (with galvanically isolated DC/AC converter)

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

/D\RXW'64& The figure below shows the layout of the DSQC327 board:


xx0100000239

A Status LEDs

112 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.4 AD Combi I/O, DSQC 327 (optional)

Connector X5 is a CAN connector further described in section "Connection and address key-
ing of the CAN bus".

&RQQHFWLRQV If supervision of the supply voltage is required, a bridge connection can be made to an
FRQQHFWRU; optional digital input. The supervision instruction must be written in the RAPID program.
This is described in the User’s Guide.
The table below shows the connections to connector X1:

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated output Out ch 1 1
Optically isolated output Out ch 2 2
Optically isolated output Out ch 3 3
Optically isolated output Out ch 4 4
Optically isolated output Out ch 5 5
Optically isolated output Out ch 6 6
Optically isolated output Out ch 7 7
Optically isolated output Out ch 8 8
Optically isolated output 0 V for outputs 1-8 9
Optically isolated output 24 V for outputs 1-8 10

&RQQHFWLRQV If supervision of the supply voltage is required, a bridge connection can be made to an
FRQQHFWRU; optional digital input. The supervision instruction must be written in the RAPID program.
This is described in the User’s Guide.
The table below shows the connections to connector X2:

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated output Out ch 9 1
Optically isolated output Out ch 10 2
Optically isolated output Out ch 11 3
Optically isolated output Out ch 12 4
Optically isolated output Out ch 13 5
Optically isolated output Out ch 14 6
Optically isolated output Out ch 15 7
Optically isolated output Out ch 16 8
Optically isolated output 0 V for outputs 9-16 9
Optically isolated output 24 V for outputs 9-16 10

&RQQHFWLRQV The table below shows the connections to connector X3:

FRQQHFWRU;

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated input In ch 1 1

3HAC 021333-001 A 113

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.4 AD Combi I/O, DSQC 327 (optional)

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated input In ch 2 2
Optically isolated input In ch 3 3
Optically isolated input In ch 4 4
Optically isolated input In ch 5 5
Optically isolated input In ch 6 6
Optically isolated input In ch 7 7
Optically isolated input In ch 8 8
Optically isolated input 0 V for inputs 1-8 9
Optically isolated input Not used 10

&RQQHFWLRQV The table below shows the connections to connector X4:

FRQQHFWRU;

8QLWIXQFWLRQ 6LJQDOQDPH ;SLQ

Optically isolated input In ch 9 1
Optically isolated input In ch 10 2
Optically isolated input In ch 11 3
Optically isolated input In ch 12 4
Optically isolated input In ch 13 5
Optically isolated input In ch 14 6
Optically isolated input In ch 15 7
Optically isolated input In ch 16 8
Optically isolated input 0 V for inputs 9-16 9
Optically isolated input Not used 10

&RQQHFWLRQV The table below shows the connections to connectors X6:

FRQQHFWRUV;

6LJQDOQDPH ;SLQ ([SODQDWLRQ

AN_ICH1 1 For test purposes only
AN_ICH2 2 For test purposes only
0V 3 0 V for In channels 1-2
0 VA 4 0 V for Out channels 1-2
AN_OCH1 5 Out channels 1
AN_OCH2 6 Out channels 2

The input current is 5.5 mA (at 24V) on the digital inputs. A grounded capacitor, to prevent
disturbances, causes a short rush of current when setting the input.
When connecting outputs, sensitive to pre-oscillation current, a series resistor (100 ohm) may
be used.

114 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.5 Analog I/O, DSQC 355 (optional)

$QDORJ,2'64&RSWLRQDO

*HQHUDO The analog I/O unit handles communication between the robot system and any external sys-
tems through analog sensors.

7HFKQLFDOGDWD

No. of analog inputs 4 (-10 V/+10 V)

No. of analog outputs 3 (-10 V/+10 V)
1 (4-20 mA))
No. of analog outputs 2 (galvanically isolated from the controller electronics)
Supply voltage 24 VDC

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

/D\RXW'64& The figure below shows the layout of the DSQC 355 board:


xx0100000238

X3 Not used
X5 DeviceNet input and ID connector
X7 Analog outputs
X8 Analog inputs

3HAC 021333-001 A 115

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.5 Analog I/O, DSQC 355 (optional)

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRUV;
DQDORJRXWSXW

xx0100000236

The table below shows the connections to connector X7:

6LJQDOQDPH ;SLQ ([SODQDWLRQ

ANOUT_ 1 Analog output 1, -10 V/+10 V
ANOUT_ 2 Analog output 2, -10 V/+10 V
ANOUT_ 3 Analog output 3, -10 V/+10 V
ANOUT_ 4 Analog output 4, 4-20 mA
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
Not used 17
Not used 18
GND 19 Analog output 1, 0 V
GND 20 Analog output 2, 0 V
GND 21 Analog output 3, 0 V
GND 22 Analog output 4, 0 V
GND 23
GND 24

116 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.5 Analog I/O, DSQC 355 (optional)

The input current is 5.5 mA (at 24V) on the digital inputs. A grounded capacitor, to prevent
disturbances, causes a short rush of current when setting the input.
Connect a resistor (100 ohm) in series when connecting outputs, sensitive to pre-oscillation
current.

&RQQHFWLRQV The figure below shows the pin configuration of the connector:
FRQQHFWRUV;
DQDORJLQSXW

xx0100000237

The table below shows the connections to connector X8:

6LJQDOQDPH ;SLQ ([SODQDWLRQ

ANIN_1 1 Analog input 1, -10 V/+10 V
ANIN_2 2 Analog input 2, -10 V/+10 V
ANIN_3 3 Analog input 3, -10 V/+10 V
ANIN_4 4 Analog input 4, -10 V/+10 V
Not used 5
Not used 6
Not used 7
Not used 8
Not used 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16
+24 V out 17 +24 VDC supply
+24 V out 18 +24 VDC supply
+24 V out 19 +24 VDC supply
+24 V out 20 +24 VDC supply
+24 V out 21 +24 VDC supply
+24 V out 22 +24 VDC supply
+24 V out 23 +24 VDC supply
+24 V out 24 +24 VDC supply

3HAC 021333-001 A 117

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.5 Analog I/O, DSQC 355 (optional)

6LJQDOQDPH ;SLQ ([SODQDWLRQ

GND 25 Analog input 1, 0 V
GND 26 Analog input 2, 0 V
GND 27 Analog input 3, 0 V
GND 28 Analog input 4, 0 V
GND 29
GND 30
GND 31
GND 32

The input current is 5.5 mA (at 24V) on the digital inputs. A grounded capacitor, to prevent
disturbances, causes a short rush of current when setting the input.
Connect a resistor (100 ohm) in series when connecting outputs, sensitive to pre-oscillation
current.

%XVVWDWXV/('V The figure and table below show the location and significance of the LEDs on the board.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

NS/MS Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ
on page 95.
RS232 Rx Green Indicates the state of the RS232 Rx line.
LED is active when receiving data. If there is no light,
check communication line and connections.
RS232 Tx Green Indicates the state of the RS232 Tx line. LED is
active when transmitting data.
If there is no light when transmission is expected,
check error messages and check also system boards
in rack.
+5VDC / +12VDC /
-12VDC Green Indicates that supply voltage is present and at correct
level.
If there is no light, check that voltage is present on
power unit and that power is present in power con-
nector. If not, check cables and connectors.
If power is applied to the unit but it does not work,
replace the unit.

118 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.6 Encoder interface unit, DSQC 354 (optional)

(QFRGHULQWHUIDFHXQLW'64&RSWLRQDO

*HQHUDO The encoder interface unit handles communication with an external conveyor:
• One encoder input (synchronization of conveyor position with robot movements). The
encoder is supplied with 24 V and 0 V, and sends position information on two chan-
nels. This information is computed by the on-board computer using quadrature decod-
ing (QDEC) to determine position and direction.
• One digital input (external start signal/conveyor synchronization point)

7HFKQLFDOGDWD

No. of encoder inputs 1

No. of digital inputs 1 (24 VDC)
Supply voltage 24 VDC
Supply source 24 V I/O or external supply

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD User reference Description Conveyor Tracking. For setup parameters, see User’s Guide - Sys-
WLRQ tem Parameters, Topic: Controller. Also see the Circuit Diagram.

/D\RXW'64& The figure below shows the layout of the DSQC 354 board:


X 20

X5 X3

xx0100000233

X3 Not used
X5 DeviceNet input and ID connector
X20 Conveyor connection

3HAC 021333-001 A 119

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.6 Encoder interface unit, DSQC 354 (optional)

(QFRGHUFRQQHF The figure below shows the encoder connections:

WLRQV
AF

AA
1
AB
2
24 VDC
3
0V
4
AC A
5 Opto
B
6 Opto
24 VDC
AD 7
0V
8
9 Opto
10
11
12 Opto
AE Opto
13
14
15
16 Opto AG

xx0100000234

AA 24 V I/O or external supply

AB 0 V I/O or external supply
AC Encoder
AD Sync switch
AE 10-16 not used
AF Encoder interface unit
AG Galvanic isolation

&RQQHFWLRQV The table below shows the connections to connector X20:

FRQQHFWRUV;
HQFRGHUDQGGLJL
WDOLQSXWFRQQHF 6LJQDOQDPH ;SLQ ([SODQDWLRQ
WLRQV 24 VDC 1 24 VDC supply
0V 2 0V
ENC 3 Encoder 24 VDC
ENC 4 Encoder 0 VDC
ENC_A 5 Encoder phase A
ENC_B 6 Encoder phase B
24 VDC 7 Synchronization switch 24 VDC
0V 8 Synchronization switch 0 V

120 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.6 Encoder interface unit, DSQC 354 (optional)

6LJQDOQDPH ;SLQ ([SODQDWLRQ

DIGIN 9 Synchronization switch digital input
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16

The figure below shows the layout of the pins in connector X20:

xx0100000235

%XVVWDWXV/('V The table below shows the significance of the LEDs on the board. For location of the LEDs
see /D\RXW'64& on page 119.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

POWER, 24 VDC Green Indicates that a supply voltage is present, and has a
level above 12 VDC.
If there is no light, check that voltage is present on
power unit and in connector X20. If not, check cables
and connectors.
If power is applied to the unit but it does not work,
replace the unit.
NS/MS Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
CAN Tx/CAN Rx Green/red See section 'HYLFH1HW%XVVWDWXV/('GHVFULSWLRQ on
page 95.
ENC 1A/1B Green Indicates phase 1 and 2 from encoder. Flashes at each
Encoder pulse. At frequencies higher than a few Hz,
flashing can no longer be observed (light will appear
weaker).
If there is no light, there is an error due to one or more
of the following reasons:
• Faulty power supply for input circuit (internal or
external).
• Defective input circuit on board.
• Short circuit or broken wire in external wiring or
connectors.
• Internal error in unit.
Constant light indicates constant high level on input
and vice versa.
No light on one LED indicates fault in one encoder
phase.

3HAC 021333-001 A 121

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.6 Encoder interface unit, DSQC 354 (optional)

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

DIGIN1 Green Digital input. Lit when digital input is active. The input
is used for external start signal/conveyor synchroniza-
tion point.
If there is no light, there is an error due to one or more
of the following reasons:
• Faulty power supply for input circuit (internal or
external).
• Faulty limit switch, photocell etc.
• Short circuit or broken wire in external wiring or
connectors.
• Defective input circuit on board.

122 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.7 Queue tracking unit, DSQC 377 (optional)

4XHXHWUDFNLQJXQLW'64&RSWLRQDO

*HQHUDO The encoder unit DSQC 377 provides connection for one encoder and one digital input (syn-
chronization switch), and includes queue tracking functions.

8VDJH The encoder is normally used for installation on a conveyor to enable the robot programs to
synchronize to the motion (position) of the conveyor (conveyor tracking).
The digital input is used for synchronization switch (also called start signal), which means
conveyor synchronization point.

7HFKQLFDOGDWD

No. of encoder inputs 1

No. of digital inputs 1 (24 VDC)
Supply voltage 24 VDC
Supply source 24 V I/O or external supply

Also see Product Specification for controller S4Cplus.

/D\RXW'64& The figure below shows the layout of the DSQC 377 board:


xx0400000751

X3 Not used
X5 DeviceNet input and ID connector
X20 Conveyor connection

3HAC 021333-001 A 123

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.7 Queue tracking unit, DSQC 377 (optional)

(QFRGHUFRQQHF The wiring diagram in the figure below shows how to connect the encoders and start signal
WLRQV switches to the encoder unit. As can be seen from the illustration, each encoder is supplied
with 24 VDC and 0 V. The encoders have two channels each. The main unit uses quadrate
decoding to compute position and direction information.

AF

AA
1
AB
2
24 VDC
3
0V
4
AC A
5 Opto
B
6 Opto
24 VDC
AD 7
0V
8
9 Opto
10
11
12 Opto
AE Opto
13
14
15
16 Opto AG

xx0100000234

AA 24 V I/O or external supply

AB 0 V I/O or external supply
AC Encoder
AD Sync switch
AE 10-16 not used
AF Encoder interface unit
AG Galvanic isolation

&RQQHFWRU;

xx0100000235

124 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.7 Queue tracking unit, DSQC 377 (optional)

X20 is the encoder and digital input connector.

The table below shows the connections to connector X20:

6LJQDOQDPH ;SLQ
24 VDC supply 1
0V 2
Encoder 1 - 24VDC 3
Encoder 1 - 0V 4
Encoder 1 - Phase A 5
Encoder 1 - Phase B 6
Digital input 1 - 24 VDC 7
Digital input 1 - 0 V 8
Digital input 1 - Signal 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16

%XVVWDWXV/('V The table below shows the significance of the LEDs on the board. For location of the LEDs
see /D\RXW'64& on page 123.

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

POWER, 24 VDC Green Indicates that a supply voltage is present, and has a
level above 12 VDC.
If there is no light, check that voltage is present on
power unit and in connector X20. If not, check cables
and connectors.
If power is applied to the unit but it does not work,
replace the unit.
NS/MS Green/red Network and module status LEDs. See section
'HYLFH1HWEXVVWDWXV/('GHVFULSWLRQ.
CAN Tx/CAN Rx Green/red See section 'HYLFH1HWEXVVWDWXV/('GHVFULSWLRQ.

3HAC 021333-001 A 125

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.7 Queue tracking unit, DSQC 377 (optional)

'HVLJQDWLRQ &RORU 'HVFULSWLRQ

ENC 1A/1B Green Indicates phase 1 and 2 from encoder. Flashes at each
Encoder pulse. At frequencies higher than a few Hz,
flashing can no longer be observed (light will appear
weaker).
If there is no light, there is an error due to one or more
of the following reasons:
• Faulty power supply for input circuit (internal or
external).
• Defective input circuit on board.
• Short circuit or broken wire in external wiring
or connectors.
• Internal error in unit.
Constant light indicates constant high level on input
and vice versa.
No light on one LED indicates fault in one encoder
phase.
DIGIN1 Green Digital inputs. Lit when digital input is active.
Normally these inputs are used as follows:
• One input used for external start signal/con-
veyor synchronization point and one input free.
• One input used for entering program number
in program queue (queue tracking) and the
other input used for conveyor synchronization
point.
If there is no light, there is an error due to one or more
of the following reasons:
• Faulty power supply for input circuit (internal or
external).
• Faulty limit switch, photocell etc.
• Short circuit or broken wire in external wiring
or connectors.
• Defective input circuit on board.

126 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.8 Relay I/O, DSQC 332 (optional)

5HOD\,2'64&RSWLRQDO

*HQHUDO The unit handles communication between the robot system and any external systems through
relay outputs and digital inputs.

7HFKQLFDOGDWD

No. of digital inputs 16 (divided into two groups of 8, galvanically isolated from
each other)
No. of relay outputs 16 (a single normally open contact, isolated from each
other)
Supply voltage 24 VDC
Supply source 24 V I/O or separate external supply

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

/D\RXW'64& The figure below shows the layout of the DSQC 332 board:


xx0100000232

A Status LEDs
X1 See below for connection tables!
X2 See below for connection tables!
X3 See below for connection tables!
X4 See below for connection tables!
X5 DeviceNet connection detailed in section &RQQHFWLRQRIWKH'HYLFH1HWEXV
on page 89!

3HAC 021333-001 A 127

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.8 Relay I/O, DSQC 332 (optional)

,OOXVWUDWLRQVLJ The figure illustrates the signal for the respective contact relay of connector X1 and X2.
QDOVIRU;DQG;

xx0400000760

A Out channel Xa (X = 1-16)

B Out channel Xb (X = 1-16)
C Supply
D Load

&RQQHFWLRQV The table below shows the connections to connector X1:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 1a 1 Contact, relay 1
Out ch 1b 2 Contact, relay 1
Out ch 2a 3 Contact, relay 2
Out ch 2b 4 Contact, relay 2
Out ch 3a 5 Contact, relay 3
Out ch 3b 6 Contact, relay 3
Out ch 4a 7 Contact, relay 4
Out ch 4b 8 Contact, relay 4
Out ch 5a 9 Contact, relay 5
Out ch 5b 10 Contact, relay 5
Out ch 6a 11 Contact, relay 6
Out ch 6b 12 Contact, relay 6
Out ch 7a 13 Contact, relay 7
Out ch 7b 14 Contact, relay 7
Out ch 8a 15 Contact, relay 8
Out ch 8b 16 Contact, relay 8

&RQQHFWLRQV The table below shows the connections to connector X2:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 9a 1 Contact, relay 9
Out ch 9b 2 Contact, relay 9
Out ch 10a 3 Contact, relay 10
Out ch 10b 4 Contact, relay 10
Out ch 11a 5 Contact, relay 11

128 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.8 Relay I/O, DSQC 332 (optional)

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 11b 6 Contact, relay 11
Out ch 12a 7 Contact, relay 12
Out ch 12b 8 Contact, relay 12
Out ch 13a 9 Contact, relay 13
Out ch 13b 10 Contact, relay 13
Out ch 14a 11 Contact, relay 14
Out ch 14b 12 Contact, relay 14
Out ch 15a 13 Contact, relay 15
Out ch 15b 14 Contact, relay 15
Out ch 16a 15 Contact, relay 16
Out ch 16b 16 Contact, relay 16

&RQQHFWLRQV The table below shows the connections to connector X3:

FRQQHFWRU;

6LJQDOQDPH ;SLQ
In ch 1 1
In ch 2 2
In ch 3 3
In ch 4 4
In ch 5 5
In ch 6 6
In ch 7 7
In ch 8 8
0 v for In ch 1-8 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16

&RQQHFWLRQV The table below shows the connections to connector X4:

FRQQHFWRU;

6LJQDOQDPH ;SLQ
In ch 9 1
In ch 10 2
In ch 11 3
In ch 12 4
In ch 13 5

3HAC 021333-001 A 129

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.8 Relay I/O, DSQC 332 (optional)

6LJQDOQDPH ;SLQ
In ch 14 6
In ch 15 7
In ch 16 8
0 v for In ch 9-16 9
Not used 10
Not used 11
Not used 12
Not used 13
Not used 14
Not used 15
Not used 16

130 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.9 Digital I/O (120 VAC), DSQC 320 (optional)

'LJLWDO,29$&'64&RSWLRQDO

*HQHUDO The unit handles communication between the robot system and any external systems through
galvanically isolated outputs and inputs.

7HFKQLFDOGDWD

No. of inputs 16 (galvanically isolated from each other)

No. of outputs 16 (galvanically isolated from each other)
Supply voltage 120 VAC

Also see Product Specification for controller S4Cplus.

)XUWKHULQIRUPD For setup parameters, see User’s Guide - System Parameters, Topic: Controller. Also see the
WLRQ Circuit Diagram.

/D\RXW'64& The figure below shows the layout of the DSQC 320 board:


xx0100000231

A Status LEDs
X1 See below for connection tables!
X2 See below for connection tables!
X3 See below for connection tables!
X4 See below for connection tables!
X5 DeviceNet connection detailed in section &RQQHFWLRQRIWKH
'HYLFH1HWEXV on page 89!

,OOXVWUDWLRQVLJ The figure illustrates the signal for the respective switch of connector X1 and X2.
QDOVIRU;DQG;

xx0400000761

3HAC 021333-001 A 131

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.9 Digital I/O (120 VAC), DSQC 320 (optional)

A Out channel Xa (X = 1:16)

B Out channel Xb (X = 1:16)
C AC supply
D Load
E Opto isolation

&RQQHFWLRQV The table below shows the connections to connector X1:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 1a 1 AC voltage to switch 1
Out ch 1b 2 AC output signal from switch 1
Out ch 2a 3 AC voltage to switch 2
Out ch 2b 4 AC output signal from switch 2
Out ch 3a 5 AC voltage to switch 3
Out ch 3b 6 AC output signal from switch 3
Out ch 4a 7 AC voltage to switch 4
Out ch 4b 8 AC output signal from switch 4
Out ch 5a 9 AC voltage to switch 5
Out ch 5b 10 AC output signal from switch 5
Out ch 6a 11 AC voltage to switch 6
Out ch 6b 12 AC output signal from switch 6
Out ch 7a 13 AC voltage to switch 7
Out ch 7b 14 AC output signal from switch 7
Out ch 8a 15 AC voltage to switch 8
Out ch 8b 16 AC output signal from switch 8

&RQQHFWLRQV The table below shows the connections to connector X2:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 9a 1 AC voltage to switch 9
Out ch 9b 2 AC output signal from switch 9
Out ch 10a 3 AC voltage to switch 10
Out ch 10b 4 AC output signal from switch 10
Out ch 11a 5 AC voltage to switch 11
Out ch 11b 6 AC output signal from switch 11
Out ch 12a 7 AC voltage to switch 12
Out ch 12b 8 AC output signal from switch 12
Out ch 13a 9 AC voltage to switch 13
Out ch 13b 10 AC output signal from switch 13
Out ch 14a 11 AC voltage to switch 14
Out ch 14b 12 AC output signal from switch 14

132 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.9 Digital I/O (120 VAC), DSQC 320 (optional)

6LJQDOQDPH ;SLQ )XQFWLRQ

Out ch 15a 13 AC voltage to switch 15
Out ch 15b 14 AC output signal from switch 15
Out ch 16a 15 AC voltage to switch 16
Out ch 16b 16 AC output signal from switch 16

,OOXVWUDWLRQVLJ The figure illustrates the signal for the respective switch of connector X3 and X4.
QDOVIRU;DQG;

xx0400000762

A Out channel Xa (X = 1:16)

B Out channel Xb (X = 1:16)
C AC supply
D Neutral
E Opto isolation

&RQQHFWLRQV The table below shows the connections to connector X3:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

In ch 1a 1 AC input signal to switch 1
In ch 1b 2 Neutral voltage to switch 1
In ch 2a 3 AC input signal to switch 2
In ch 2b 4 Neutral voltage to switch 2
In ch 3a 5 AC input signal to switch 3
In ch 3b 6 Neutral voltage to switch 3
In ch 4a 7 AC input signal to switch 4
In ch 4b 8 Neutral voltage to switch 4
In ch 5a 9 AC input signal to switch 5
In ch 5b 10 Neutral voltage to switch 5
In ch 6a 11 AC input signal to switch 6
In ch 6b 12 Neutral voltage to switch 6
In ch 7a 13 AC input signal to switch 7
In ch 7b 14 Neutral voltage to switch 7
In ch 8a 15 AC input signal to switch 8
In ch 8b 16 Neutral voltage to switch 8

3HAC 021333-001 A 133

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.6.9 Digital I/O (120 VAC), DSQC 320 (optional)

&RQQHFWLRQV The table below shows the connections to connector X4:

FRQQHFWRU;

6LJQDOQDPH ;SLQ )XQFWLRQ

In ch 9a 1 AC input signal to switch 1
In ch 9b 2 Neutral voltage to switch 1
In ch 10a 3 AC input signal to switch 2
In ch 10b 4 Neutral voltage to switch 2
In ch 11a 5 AC input signal to switch 3
In ch 11b 6 Neutral voltage to switch 3
In ch 12a 7 AC input signal to switch 4
In ch 12b 8 Neutral voltage to switch 4
In ch 13a 9 AC input signal to switch 5
In ch 13b 10 Neutral voltage to switch 5
In ch 14a 11 AC input signal to switch 6
In ch 14b 12 Neutral voltage to switch 6
In ch 15a 13 AC input signal to switch 7
In ch 15b 14 Neutral voltage to switch 7
In ch 16a 15 AC input signal to switch 8
In ch 16b 16 Neutral voltage to switch 8

134 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.1 Communication, serial links

&RPPXQLFDWLRQ

&RPPXQLFDWLRQVHULDOOLQNV

*HQHUDO The robot has three serial channels, which can be used by the customer to communicate with
printers, terminals, computers, and other equipment (see the figure in "Connections" below).
• COM1 (computer system) - RS 232 115 kbps. This was formerly referred to as &RP
• COM2 - RS 232 with RTS-CTS-control and support for XON/XOFF, transmission
speed 300 - 38 400 bps. This was formerly referred to as 6,2
• COM3 - RS 422 full duplex TXD4, TXD4-N, RXD4, RXD4-N, transmission speed 300 -
38 400 bps. This was formerly referred to as 6,2
• )RUWHPSRUDU\XVH: MC/CONSOLE - RS 232 115 kbps. This was formerly referred to
as &RP

)XUWKHULQIRUPD • For setup parameters, see User's Guide - System Parameters, Topic: I/O Signals.
WLRQ • Circuit Diagram.
• Location in the cabinet (see figure in section "Connection to screw terminals").

7HFKQLFDOGDWD See Product Specification for controller S4Cplus. Separate documentation is included when
the option RAP Serial link is ordered.

&RQQHFWLRQV The figure below shows the connection of serial channels.

xx0100000219

A External computer

Customer terminals, on base connector board: X10 (COM2) and X9 (COM3), see section
"Connection to screw terminals".

3HAC 021333-001 A 135

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.1 Communication, serial links

&RQQHFWLRQVRQ Standard RS232 port.

'64&&20 The figure below shows the pin configuration of the connector.

5
6

9
1
xx0100000220

The table below shows the signals from the COM1 (RS232):

6LJQDO 3LQ 'HVFULSWLRQ

DCD 1 Data carrier Detect
RX 2 Receive Data
TX 3 Transmit Data
DTR 4 Data Terminal Ready
GND 5 Signal Ground
DSR 6 Data Set Ready
RTS 7 Request To Send
CTS 8 Clear To Send
RI 9 Ring Indicator
NC 10 Not Connected

&RQQHFWLRQVRQ The figure below shows the pin configuration of the connector.
'64&'VXE
FRQQHFWRU;
&20 5
6

9
1

xx0100000220

The table below shows the connections to connector X10.

&206LJQDOQDPH ;SLQ
1
RxD (Receive Data) 2
TxD (Transmit Data) 3
DTR (Data Terminal Ready) 4
0V 5
DSR (Data Ready Set) 6
RTS N (Request To Send N) 7
CTS (Clear To Send) 8
9

136 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.1 Communication, serial links

&RQQHFWLRQVRQ The figure below shows the pin configuration of the connector.
'64&'VXE
FRQQHFWRU;
&20 5
6

9
1
xx0100000220

The table below shows the connections to connector X9.

&206LJQDOQDPH ;VRFNHW
TxD (Transmit Data) 1
TxD N (Transmit Data N) 2
RxD (Receive Data) 3
RxD N (Receive data N) 4
0V 5
DATA (Data Signals in Half Duplex Mode) 6
DATA N (Data Signals in Half Duplex Mode N) 7
DCLK (Data Transmission Clock) 8
DCLK N (Data Transmission Clock N) 9

&RQQHFWLRQVWR The figure below shows the MC/CONSOLE connection behind the service hatch:
0&&2162/(

xx0100000218

A External computer

3HAC 021333-001 A 137

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.1 Communication, serial links

Standard RS232 port intended for temporary use, e.g. connection of laptop/PC.
The table below shows the signals on the MC/CONSOLE (RS232).

6LJQDO 3LQ 'HVFULSWLRQ

RX 2 Receive Data
TX 3 Transmit Data
GND 5 Signal Ground

138 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.2 Communication, Ethernet

&RPPXQLFDWLRQ(WKHUQHW

*HQHUDO The robot has two Ethernet channels available:

• LAN (connected to the Main computer)
• Service (connected to the I/O computer)

&RQQHFWLRQRI The figure below shows an outline diagram of the Ethernet TCP/IP.
/$10DLQFRP
SXWHU A B C

Ethernethub
xx0100000217

A External computer
B Controller (M2000) Robot 1
C Controller (M2000A) Robot 2

Used for connection of shielded twisted-pair Ethernet (TPE), or as defined in IEEE 802.3: 10/
100 BASE-T. Maximum node-to-node distance 100 meter. The main computer board has no
termination for a cable shield. The cable shield must be grounded at the cabinet wall with a
cable gland. 10BASE-T is a point-to-point net, connected via a HUB, see the figure above.

6LJQDO ;3LQ 'HVFULSWLRQ

TX+ 1 Transmit data line +
TX- 2 Transmit data line -
RX+ 3 Receive data line +
NC 4 Not Connected
NC 5 Not Connected
RX- 6 Receive data line -
NC 7 Not Connected
NC 8 Not Connected

3HAC 021333-001 A 139

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.2 Communication, Ethernet

There are two variants of main computer boards, and these are DSQC 500 and DSQC 540
(newer variant from 2004).
The figure below shows the main computer board front of DSQC 500.
1

;
/$1

3:5

+''

67$786

;

xx0100000216

The figure below shows the main computer board front of DSQC 540.

xx0400000759

140 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.2 Communication, Ethernet

&RQQHFWLRQRI Used for connection of a laptop to the service outlet on the front of the controller cabinet
6HUYLFH,2&RP (behind service hatch).
SXWHU The figure below shows how to connect a laptop to the service outlet (M2000A).

Ethernet

xx0100000215

Separate documentation is included when the option Ethernet services is ordered. For setup
parameters, see the manual 8VHU
V*XLGH6\VWHP3DUDPHWHUV7RSLF,26LJQDOV.
Art. no. for the manual is specified in section 'RFXPHQWUHIHUHQFHVin the 3URGXFWPDQXDO
UHIHUHQFHLQIRUPDWLRQ.

3HAC 021333-001 A 141

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.4.7.3 External operator’s panel

([WHUQDORSHUDWRU
VSDQHO

*HQHUDO All necessary components are supplied, except for the external enclosure.

'LPHQVLRQVIRU Install the assembled panel in a housing which satisfies protection class, IP 54, in accordance
LQVWDOODWLRQ with IEC 144 and IEC 529!
The figure below shows the main dimensions of the external operator’s panel.
B A

M8 (x4)
M4 (x4)
62

C
45 °

70

140
184
200

90

ø 5 (x2)
1 55
F

xx0100000214

A Holes for operator’s panel

B Holes for flange
C Required depth: 200 mm
D External panel enclosure (option)
E Holes for teach pendant unit (TPU) holder
F Teach pendant unit (TPU) connector
G Connection to the controller

142 A 3HAC 021333-001

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3.5.1 Inspection before start-up

6WDUWXS

,QVSHFWLRQEHIRUHVWDUWXS

*HQHUDO Perform the following checks before starting up the robot system.

&KHFNWKDW  the controller mains section is protected with fuses.

 the electrical connections are correct and correspond to the identification plate on the con-
troller.
 the teach pendant and peripheral equipment are properly connected.
 any limiting devices that establish the restricted space (when utilized) are installed.
 the physical environment is as specified.
 the operating mode selector on the operator’s panel is in the Manual mode position.
 when external safety devices are used, check that these have been connected or that the
following circuits in either XS3 (connector on the outside left cabinet wall) or X1-X4 (screw
terminals on the panel unit) are strapped.

Device XS3 Panel unit

External limit switches A5-A6, B5-B6 X1.11-12, X2.11-12
External emergency stop A3-A4, B3-B4 X1.3-4, X2.3-4
External emergency stop internal 24 V A1-A2, B1-B2 X1.7-8, X2.7-8
General stop + A11-A12, B11-B12 X3.10-12, X4.10-12
General stop - A13-A14, B13-B14 X3.7-8, X4.7-8
Auto stop + A7-A8, B7-B8 X3.11-12, X4.11-12
Auto stop - A9-A10, B9-10 X3.7-9, X4.7-9
Motor off clamping A15-A16, B15-16 X1.5-6, X2.5-6

3HAC 021333-001 A 143

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.5.2 Start-up

6WDUWXS

*HQHUDO  Switch on the mains switch on the cabinet.

 The robot performs its self-test on both the hardware and software, which takes approxi-
mately 1 minute.
 If the robot is not supplied with the software already installed, install the software as
described in section ,QVWDOODWLRQRIFRQWUROOHUVRIWZDUH on page 145.
A welcome message is shown on the Teach Pendant Unit display.
 If the controller is implemented with the Absolute Accuracy software, the calibration offset
values must be loaded from the disk Manipulator Parameters. This is described in the
8VHUV*XLGH for the BaseWare Option - Absolute Accuracy.
 To switch from MOTORS OFF to MOTORS ON, press the enabling device on the teach
pendant.
 Update the revolution counters and check the calibration position as described in the Prod-
uct Manual for the manipulator, chapter &DOLEUDWLRQ.
 ,5%Check the position of the spiral cable in the center tube sleeve. Correct position
is described in the Product Manual for the IRB 940, chapter &DOLEUDWLRQ.
 When the controller, with the manipulator electrically connected, is powered up for the first
time, ensure that the power supply is connected for at least 36 hours continuously, in order
to fully charge the batteries for the serial measurement board. It takes approx. 4 hours to
fully charge a computer system battery.
 After having checked the above, verify that:
• the start, stop and mode selection (including the key lock switches) control devices
work as intended.
• each axis moves and is restricted (if possible) as intended.
• emergency stop and safety stop (where included) circuits and devices are functional.
• it is possible to switch off the mains switch in a prescribed way.
• programming and program running work correctly.
• the safeguarding is in place.
• at reduced speed, the robot operates properly and has the capability to handle the
product or workpiece.
• in automatic (normal) operation, the robot operates properly and has the capability to
perform the intended task at the rated speed and load.
 The robot is now ready for operation.

2SHUDWLQJWKH Starting and operating the robot is described in the User’s Guide. Before start-up, make sure
URERW that the robot can not collide with any other objects in the working space.

144 A 3HAC 021333-001

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3.6.1 Loading system software

,QVWDOODWLRQRIFRQWUROOHUVRIWZDUH

/RDGLQJV\VWHPVRIWZDUH

*HQHUDO The robot system may be delivered with or without system software. When the system is not
delivered with software, it must be downloaded in one of a number of ways.

6RIWZDUHLQVWDOOHG If the robot controller is ordered with the software installed on delivery, the controller soft-
RQGHOLYHU\ ware and settings are already stored in the storage memory and the system is ready to use.

6RIWZDUHQRW If the robot controller is ordered and delivered without software or if you want to reconfigure
LQVWDOOHGRQ your system, the RobInstall tool must be used to install the controller software. The RobIn-
GHOLYHU\ stall tool is included on the RobotWare CD-ROM (see section 5RERW:DUH&'520 on page
147). The RobInstall tool can be used both for creation of the controller software and for
downloading it to the controller system.

7\SHVRIVRIWZDUH
ORDGLQJ

xx0100000192

A RobotWare CD-ROM to install RobInstall and System Pack on PC

B Floppy Disks
C IOC Ethernet (service) with delivered boot cable UTP-X
D Connected to IOC
E MC Ethernet (LAN) network in workshop

When downloading, the controller software can be transferred to the controller storage mem-
ory in three ways as shown in the figure above.
• using floppy disks,
• using Ethernet connected direct to the IO computer (IOC) service outlet on the front of
the controller cubicle,
• using Ethernet connected via a local area network (LAN) to the main computer (MC).

3HAC 021333-001 A 145

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.1 Loading system software

%RRW,PDJH The transfer and installation of the controller software to the controller storage memory via
Ethernet or floppy disks is executed by a basic program named Boot Image.
This basic program must always be in the storage memory. When starting the controller, with
no controller software installed, Boot Image will start and ask the operator for controller
software installation instructions. If the controller software is already installed and a warm
start is performed, Boot Image is not used. The installed controller software can be deleted
by a cold start and then the Boot Image will be reactivated.

146 A 3HAC 021333-001

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3.6.2 RobotWare CD-ROM

5RERW:DUH&'520
The CD contains all the System software and should therefore be treated and stored carefully.

5RERW:DUH&' The RobotWare CD-ROM contains the following:

520FRQWHQWV

&RQWHQWV 'HVFULSWLRQ
1. RobInstall A PC tool used to create and install the controller operating sys-
tem in the robot control system.
2. Documentation On-line documentation for the RobInstall application and the
Controller Operating System Package.
3. Controller OS Controller Operating System Package for S4Cplus. This pack-
Package age includes all the software needed to create the controller
operating system with any ordered options. Please note that it
is possible to install different releases with different versions of
the same system package (see section 0HGLDSRROLQWKH3& on
page 175).
4. Test Signal A tool (created in LabView) for viewing MotionTest Signals
Viewer (oscilloscope function) and also for logging these signals.
5. FTP Client The CD also includedes a so called FTP client named Voyager.
Please note that this is not an ABB product but a shareware
program, which means that it can be installed and used for a
limited time, but that it must be registered for permanent use.
Registering means that a certain fee must be paid to the vendor.
The FTP client is used to transport files manually between the
PC and the robot controller storage memory. These actions are
carried out in the same way as in a file manager or in Windows
Explorer.

,QVWDOODWLRQRIWKH This section describes how to install the software delivered on the RobotWare CD-ROM onto
5RERW:DUHRQWKH a PC hard drive, to be transferred to the robot system.
3&H[FHSW)73  Insert the CD in your reader.
&OLHQW
 The Install Shield will automatically start and guide you through the install process (if it
does not start, double-click the CD icon on your PC). When the setup type window is dis-
played, it is recommended to select the Custom button. Then Next button will open the
Select Components window, where normally all the four options, RobInstall, Documenta-
tion, Controller OS Package and Test Signal Viewer should be marked as selected. Always
make sure to use the latest version of RobInstall, which is found on the RobotWare CD-
ROM.

,QVWDOODWLRQRIWKH This section describes how to install the FTP Client onto a PC hard drive.
)73&OLHQWRQWKH  In the Explorer, select and open the directory "ftp" on the CD.
3&
 Double-click the file ftpvsetup.exe.
The Install Shield for the FTP client will start and guide you through the installation. Please
read the "Readme" file for information about license regulations.

3HAC 021333-001 A 147

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.3 Installing new Robot Controller Software with RobInstall

,QVWDOOLQJQHZ5RERW&RQWUROOHU6RIWZDUHZLWK5RE,QVWDOO

*HQHUDO Since most systems have the operating system pre-installed on delivery, the RobotWare CD-
ROM is normally not needed. However it should be used when:
• creating a new controller operating system,
• changing the current operating system configuration, e.g. concerning included
options.

1RPHQFODWXUH In the text dealing with RobInstall, the following nomenclature is used:

&RQFHSW 0HDQV
System pack This is the RobotWare Controller Operating System Package for S4Cplus,
including all options, even if they are not ordered and activated.
Key This is a text string, or a special file with the text string, which is used to
define and open both the BaseWare and all ordered RobotWare options.
System This is a complete controller software, i.e. controller operating system,
based on the system pack and the key. It can also include any user files to
be added to the home directory on the controller storage memory.

.H\VWULQJ RobotWare key strings are compatible forward, i.e. a release key revision is not possible to
use for an older System Package that does not support the release key.
The key string is found on a label of the CD-ROM cover and/or in the paper that comes with
the CD-ROM delivery.

+RZWRXVH5RE Robinstall is used to create and install the controller software in the S4Cplus robot controller.
,QVWDOO With RobInstall, you can:
• create a new system,
• update an existing system,
• download a system to the controller using the Ethernet connection,
• create Boot Disks to transfer the system to the Controller.

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Make sure RobInstall is
installed. If not, install it
according to the instruc-
tions in section ,QVWDOODWLRQ
RIWKH5RERW:DUHRQWKH
3&H[FHSW)73&OLHQW on
page 147.
2. Click the start button on
your PC and select pro-
grams/ABB Robotics/Rob-
Install/RobInstall.

148 A 3HAC 021333-001

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3.6.3 Installing new Robot Controller Software with RobInstall

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

3. The RobInstall start win-
dow will open.

xx0100000185

3HAC 021333-001 A 149

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.4 Create a new Robot Controller System

&UHDWHDQHZ5RERW&RQWUROOHU6\VWHP

6HWWLQJXSWKH
V\VWHP
6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. Start RobInstall as
described in section +RZ
WRXVH5RE,QVWDOO on page
148.
2. Choose 1HZ to create a
new Robot Controller
system as shown in the
figure.

xx0100000179

3. Enter a name for the new

controller system.
The recommended max
length for the System
name is 16 characters.
That secures full support
in the File Manager. The
File Manager can only
display files and directo-
ries which has a name
length of maximum 16
characters.
Select a saving location
or use the default direc-
tory, normally "Program
Files\ABB Robotics\sys- xx0100000180

tem" (see the figure to

the right, position 1).
4. Enter the RobotWare key
or add from file. If added
from a file, files with the
extension .kxt should be
used (see the figure
above, position 2).

150 A 3HAC 021333-001

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3.6.4 Create a new Robot Controller System

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

5. Press 2.. The config-
ured system will be dis-
played in the next
window (see the figure to
the right).

xx0100000181

6. If no external options or
parameters are to be
added or changed, press
)LQLVKto create the new
controller system. Other-
wise press 1H[Wto con-
tinue to "Additional Keys"
(see section $GGRU
UHPRYHH[WHUQDORSWLRQV
on page 151).

$GGRUUHPRYH
H[WHUQDORSWLRQV
6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. To add or remove external
options, press 1H[W in the
screen shown in the last
figure in section "Setting
up the system" or click on
"Additional Keys" in the
menu to the left.

xx0100000182

2. Enter the key string for the

selected option and press
$GG.H\ to list, or pres-
s$GGNH\IURPILOH to select
a key string file.
3. To remove additional keys,
select the key in the
Included Additional Keys
list and press 5HPRYH.H\
.

3HAC 021333-001 A 151

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.4 Create a new Robot Controller System

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

4. Press )LQLVKto create the
controller system or press
1H[Wto continue to
"Parameter Data" (see
section $GGRUUHPRYH
DGGLWLRQDOV\VWHPSDUDPH
WHUV on page 152).

$GGRUUHPRYH
DGGLWLRQDOV\VWHP
SDUDPHWHUV 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. To add or remove addi-
tional parameters, press
1H[W in the screen shown
in the last figure in section
Add or remove external
options or click on
"Parameter Data" in the
menu to the left.

xx0100000183

2. Press $GG to load manip-

ulator calibration data (see
the figure above, position
1). This is the calib.cfg file
delivered on the Manipu-
lator Parameter disk.
3. To remove manipulator
calibration data, press
5HPRYH.
4. Press $GG to load addi-
tional system parameters,
see pos. 2. All system
parameter files added
here will be automatically
loaded together with the
system, when the control-
ler is restarted with the
new system.
5. To remove additional
parameters, select the
parameter in the "Loaded
Additional Parameters" list
and press 5HPRYH.
6. Press )LQLVKto create the
controller system or press
1H[W to continue to
"Options" (see section
"Change options or sys-
tem pack revision").

152 A 3HAC 021333-001

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3.6.4 Create a new Robot Controller System

&KDQJHRSWLRQV
RUV\VWHPSDFN
UHYLVLRQ 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. To change the option config-
uration, press 1H[W in the
screen shown in the figure
below or click on "Options"
in the menu to the left.

xx0100000184

2. To change the Teach Pen-

dant Unit language, robot
type, or software options,
press 2SWLRQV (see the fig-
ure above, position 1).
3. Normally the latest release
or revision of all system
packages and option pack-
ages stored in the media
pool (see section 0HGLD
SRROLQWKH3& on page 175)
will be used. If an earlier
revision should be used,
uncheck the check mark
and press 5HY6HOHFW(see
the figure above, position
2). In the new window select
the system package to use
and press 2..
4. If you want the system to
start up in query mode, put a
mark in the query mode
selection square. For further
details of the query mode,
see section +RZWR6WDUWLQ
4XHU\0RGH on page 173.
5. Press )LQLVKto create the
controller system or press
1H[W to view the current
configuration.

3HAC 021333-001 A 153

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.5 Update the Robot Controller image

8SGDWHWKH5RERW&RQWUROOHULPDJH

$FWLRQV

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. To update an existing con-
troller system, press 8SGDWH
, see the figure below.

xx0100000189

2. Select a system in the sys-

tem list and press 2., see
the figure above. Please
note that a pop up menu can
be shown by clicking right
mouse button. With this
menu Copy, Rename or
Delete can be selected for
the marked system.

xx0100000190

3. The window displaying the

current configuration of the
system will be shown. Follow
the instructions in sections
"Add or remove external
options", "Add or remove
additional system parame-
ters" or "Change options or
system pack revision" (in
section &UHDWHDQHZ5RERW
&RQWUROOHU6\VWHP on page
150) to modify the system.

154 A 3HAC 021333-001

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3.6.6 Transfer Robot Controller System using Ethernet connection

7UDQVIHU5RERW&RQWUROOHU6\VWHPXVLQJ(WKHUQHWFRQQHFWLRQ

6HOHFWLQJW\SHRI Before a system can be downloaded to a robot controller using the RobInstall tool some prep-
VHWXS arations and set up must be done. This may be done using one of the three connections
described below:

WKHQVHHLQVWUXFWLRQVLQ
,I\RXDUHXVLQJ DQGFRQWLQXHLQVHFWLRQ
VHFWLRQ
a direct connection "If using a direct connection "Download Robot Controller
between PC and IOC between PC and IOC service System" below!
service outlet on con- outlet on controller" below!
troller
Network Intranet con- "If using Network Intranet con- "Download Robot Controller
nection with fixed IP nection with fixed IP addresses " System" below!
addresses below!
Network Intranet con- "If using Network Intranet con- "Download Robot Controller
nection with DHCP nection with DHCP " below! System" below!
(Dynamic Host Config-
uration Protocol)

,IXVLQJDGLUHFW
FRQQHFWLRQ
EHWZHHQ3&DQG 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
,2&VHUYLFHRXWOHW
1. Connect a patch-cable
RQFRQWUROOHU
between the Ethernet con-
nection on the front of the
controller and the corre-
sponding connection on
the PC/Laptop.
2. Make sure that the Net-
work protocol is set for
TCP/IP properties.
3. Change the TCP/IP Prop-
erties in accordance with
the following table and fig-
ure:
• Parameter/Value:
IP Address=
192.168.125.82
• Parameter/Value:
Subnet Mask=
255.255.255.240
• Parameter/Value:
Default Gateway=
192.168.125.81

xx0100000178

3HAC 021333-001 A 155

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.6 Transfer Robot Controller System using Ethernet connection

,IXVLQJ1HWZRUN
,QWUDQHWFRQQHF
WLRQZLWKIL[HG,3 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
DGGUHVVHV
1. Make sure that the Network protocol is set for TCP/IP
properties.
2. Change the TCP/IP Properties in accordance with the val-
ues to be used for IP address, Subnet mask and Gateway.
3. Perform a X-START (see section ;67$57FKDQJHDFWLYH
FRQWUROOHUV\VWHP on page 171) or C-START (see section
&67$57&ROGVWDUWGHOHWHWKHDFWLYHV\VWHP on page
172) on the S4Cplus controller.
4. Configure the IP address to be used for the robot control-
ler from the TPU.

,IXVLQJ1HWZRUN
,QWUDQHWFRQQHF
WLRQZLWK'+&3 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. Read Ethernet MAC-id on the Teach Pendant Unit (see
section /$16HWWLQJV:LQGRZ on page 166).

'RZQORDG5RERW
&RQWUROOHU6\V
WHP

Before downloading, check the following:

Make sure there is at least 25 Mb free disk space on the controller mass storage memory. For
information on how to perform a manual storage capacity check, see section +DQGOLQJPDVV
PHPRU\VWRUDJHFDSDFLW\ on page 179.
Make sure that the robot controller displays the Start Window on the Teach Pendant Unit (see
section 6WDUWZLQGRZ on page 162).

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. To download a control-
ler system, press
'RZQORDG as in the
figure to the right:

xx0100000176

156 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.6 Transfer Robot Controller System using Ethernet connection

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

2. Select a target system If a direct connection is used with the patch cable
as in the figure, posi- between the PC and the controller front, then just select
tion 1. the default IP address (192.168.125.1) and "Direct"
option.
In other cases, write the correct IP address for the robot
controller and select "Hostname or IP-address". RobIn-
stall will store already used IP addresses, which can later
be selected with the down arrow.
3. Type your username
and password if
required by the robot
controller as in the fig- 1
ure to the right, posi-
tion 2.

xx0100000177

4. Test the connection by

pressing 7HVW&RQQHF
WLRQand press 2. if a
connection is estab-
lished.
5. Select a system in the
list on the left and
press 2. as in the fig-
ure below. Please note
that it is possible to
select another system
pool than the shown
one (in such case be
sure to select the sys-
tem pool directory, not
the system itself on the
lower level).

xx0100000175

6. RobInstall will now cre- After downloading it is possible to restart the controller
ate a system file and with the new downloaded controller system. Otherwise,
download it to the con- the controller may be restarted from the Teach Pendant
troller. Unit as detailed in section 5HERRW:DUPVWDUWDSSO\
FKDQJHGVHWWLQJV on page 170.

3HAC 021333-001 A 157

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.7 Transfer Robot Controller System using floppy disks

7UDQVIHU5RERW&RQWUROOHU6\VWHPXVLQJIORSS\GLVNV
Before downloading, make sure:
- There is at least 25 Mb free disk space on the controller mass storage memory. For informa-
tion on how to perform a manual storage capacity check, see section +DQGOLQJPDVVPHPRU\
VWRUDJHFDSDFLW\ on page 179.
- That the robot controller displays the Start Window on the Teach Pendant Unit (see section
6WDUWZLQGRZ on page 162).
- An optional floppy disk drive is installed in the robot controller.

&UHDWH%RRW'LV
NHWWHVIURP5RE
,QVWDOO 6WHS $FWLRQ ,OOXVWUDWLRQ,QIR
1. Press &UHDWH%RRW
'LVN as in the figure
below.

xx0100000173

158 A 3HAC 021333-001

 ,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.7 Transfer Robot Controller System using floppy disks

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

2. Select a system in the
list on the left and
press 2. as in the
figure below.
RobInstall will now
create an image file
and estimate the
number of disks
needed.

xx0100000175

xx0100000188

3. Insert a formatted
1.44 Mb diskette into
the disk drive.
4. Press &RQWLQXH to
start copy the Robot
Controller System
image to the disks.
5. Use the finished
floppy disks to boot
your system as
described in section
%RRW'LVN:LQGRZ on
page 164.

3HAC 021333-001 A 159

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.6.8 RobInstall preferences

5RE,QVWDOOSUHIHUHQFHV

&XVWRPL]LQJ5RE RobInstall may be customized to suit particular requirements.

,QVWDOO

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. To customize RobInstall
for new programs and
optional products, press
Preferences as shown in
the figure. See also sec-
tion 6\VWHPGLUHFWRU\
VWUXFWXUH on page 175.

xx0100000186

2. To select another media

pool (see section 0HGLD
SRROLQWKH3& on page
175), press Select
Media Pool as shown in
the figure, position 1.

xx0100000187

3. To add a new system

package or option pack-
age to the media pool,
press Import Program as
shown in the figure,
position 2. Also see sec-
tion 6\VWHPGLUHFWRU\
VWUXFWXUH on page 175.

160 A 3HAC 021333-001

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3.7.1 BootImage

5RERWFRQWUROOHU

%RRW,PDJH

*HQHUDO The BootImage is a basic program which is used to start up the system from "scratch".

3XUSRVHRIWKH This program is already installed in the controller at delivery and is used to:
SURJUDP • restart the system
• load the system from boot disks or network connections
• set or check network settings
• choose a system from the mass storage memory

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,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.7.2 Start window

6WDUWZLQGRZ

:KHQLVLW
VKRZQ"

xx0100000168

The start window displays the start menu and will appear in the following cases:
• When no controller operating system is installed at power on.
• After X-START (see section ;67$57FKDQJHDFWLYHFRQWUROOHUV\VWHP on page 171).
• After C-START (see section &67$57&ROGVWDUWGHOHWHWKHDFWLYHV\VWHP on page
172).

3RVVLEOHDFWLRQV From this window you can choose to do one of the following:

Restart the system, The BootImage will be re-executed, used to apply changes in the system settings (see section
5HERRW 5HERRW:LQGRZ on page 163).

Load a system (See section %RRW'LVN:LQGRZ on page 164.)

from diskettes,
%RRW'LVNV

Set the network Set network settings for the Main Computer or check how to configure your PC (see section
settings, 1HWZRUN 1HWZRUN6HWWLQJV:LQGRZ on page 165).
6HWWLQJV

Choose a system If there is one or more systems in the mass storage memory, you can choose to activate one
from the mass stor- of them (see section 6\VWHPVHOHFWLRQZLQGRZ on page 169).
age memory,
6HOHFW6\VWHP

162 A 3HAC 021333-001

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3.7.3 Reboot Window

5HERRW:LQGRZ

:KHQLVLW The Reboot window will be displayed if any of the system settings are changed or when
VKRZQ" 5HERRW is pressed in the Start window as shown in the figure below.

xx0100000169

Button Function
YES Restarts the system
NO Returns to the start window

3HAC 021333-001 A 163

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3.7.4 Boot Disk Window

%RRW'LVN:LQGRZ

:KHQLVLW The Boot Disk window will be displayed when %RRW'LVNVis pressed in the Start window as
VKRZQ" shown in the figure in section 6WDUWZLQGRZ on page 162

+RZWRFUHDWH Information on how to create boot disks from RobInstall can be found in section 7UDQVIHU
ERRWGLVNV 5RERW&RQWUROOHU6\VWHPXVLQJIORSS\GLVNV on page 158

/RDGWKHV\VWHP

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Insert the correct dis-
kette in the floppy disk
drive and press 2.. If
the diskette is alright,
the system will be
loaded.
&$1&(/removes all
previously loaded data
and returns to the Start
window as shown in the
figure in section 6WDUW
ZLQGRZ on page 162
xx0100000170

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3.7.5 Network Settings Window

1HWZRUN6HWWLQJV:LQGRZ

:KHQLVLW The Network Settings window will be displayed when Network Settings is pressed in the
VKRZQ" Start window as shown below.

xx0200000209

LAN Settings Press to configure the Main Computer for communication with a PC on a
Local Area Network (LAN). Also see /$16HWWLQJV:LQGRZ on page 166!
Service Settings Press to view the required settings for the PC to communicate with the I/
O Computer. Also see 6HUYLFH6HWWLQJV:LQGRZ on page 168!
CANCEL Press to return to the Start window as shown in figure in 6WDUWZLQGRZ on
page 162.

3HAC 021333-001 A 165

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.7.6 LAN Settings Window

/$16HWWLQJV:LQGRZ

:KHQLVLW The LAN Settings window will be displayed when /$16HWWLQJVis pressed in the Network
VKRZQ" Settings window as shown in the figure in section 1HWZRUN6HWWLQJV:LQGRZ on page 165.

en0100000256

NONE After the system is rebooted, remove the IP settings.

CANCEL Returns to the Start window, as shown in the figure in section 6WDUWZLQGRZ
on page 162, without changing any settings.

1RGHLGHQWLILFD
WLRQ
3DUDPHWHU 7\SH 'HVFULSWLRQ
MAC ID Node identification The Main Computer’s ethernet address.
Current IP Node identification The Main Computer’s current IP address. This row is
blank if the LAN Settings are not defined.
IP Network setting Space for typing in a new IP address, for the Main
Computer or the DHCP server. See &RQILJXUHIRU
IL[HG,3QHWZRUNand &RQILJXUHIRU'+&3GLVWULEXWHG
,3QHWZRUN below.
(Subnet mask) Network setting Shows the subnet mask of the network.
Only visible when configured for fixed IP.
(Gateway) Network setting Shows the gateway IP for the network.
Only visible when configured for fixed IP.

&RQILJXUHIRU  Press ),;,3.

IL[HG,3QHWZRUN  Fill in the assigned IP address for the Main Computer, and the Subnet Mask and Gateway
for the Network and press 2..
You will be asked to reboot the system.
 Press <(6 to make the new setting take effect.

&RQILJXUHIRU  Press '+&3

'+&3GLVWULEXWHG The value for IP will change to DHCP.
,3QHWZRUN

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3.7.6 LAN Settings Window

 Press OK.
You will be asked to reboot the system.
 Press <(6 to make the new setting take effect.

3HAC 021333-001 A 167

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3.7.7 Service Settings Window

6HUYLFH6HWWLQJV:LQGRZ

:KHQLVLW The Service Settings window will be displayed when 6HUYLFH6HWWLQJVis pressed in the Net-
VKRZQ" work Settings window as shown in the figure in section 1HWZRUN6HWWLQJV:LQGRZ on page
165.

en0100000257

OK returns to the Start window as shown in the figure in section 6WDUWZLQGRZ

on page 162.

6HUYLFH6HWWLQJ

3DUDPHWHU 'HVFULSWLRQ
IP (service setting) The IP Address for the I/O Computer.
IP Required to configure your PC’s network settings for communication
between RobInstall and the I/O Computer.
Subnet mask Required to configure your PC’s network settings for communication
between RobInstall and the I/O Computer.
Gateway Required to configure your PC’s network settings for communication
between RobInstall and the I/O Computer.

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3.7.8 System selection window

6\VWHPVHOHFWLRQZLQGRZ

:KHQLVLW The Select System window will be displayed when 6HOHFW6\VWHPis pressed in the Start win-
VKRZQ" dow, as shown in the figure in section 6WDUWZLQGRZ on page 162.

xx0100000171

CANCEL Returns to the Start window as shown in the figure in section 6WDUWZLQGRZ
on page 162.

+RZWRVHOHFW The window shows all systems installed on the controller mass storage memory.
V\VWHP

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Select by moving the X
to a desired system and
press 2.
The system will reboot
with the new system and
then display the Wel-
come window as shown
in the figure.

xx0100000172

3HAC 021333-001 A 169

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.7.9 How to perform a Restart

+RZWRSHUIRUPD5HVWDUW

*HQHUDO Performing a restart may be done in a number of ways. These are detailed below:

5HERRW:DUP When executing a Warm start, the system reboots with the current system, e.g. to make new
VWDUWDSSO\ or changed settings take effect.
FKDQJHGVHWWLQJV

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Press the button 0LVFHOODQHRXVand select 6HU Miscellaneous button:
YLFHZLQGRZor 6\VWHP3DUDPHWHU window

xx0100000194

2. Select 5HVWDUWfrom the )LOHmenu and press 2..

The system reboots and returns to the Welcome
window as shown in the figure in section +RZWR
VHOHFWV\VWHP on page 169.

367$57UHLQVWDO A P-Start will warm start the current system, with a reinstallation of the RAPID language and
ODWLRQRI5$3,' all auto-loaded modules. This means that all RAPID program and system modules currently
loaded in the working memory will be closed, and thus have to be reloaded again after the P-
Start, with the exception of such modules that are automatically loaded, due to settings in the
System Parameters/Controller/Task Modules.

6WHS $FWLRQ ,OOXVWUDWLRQLQIR

1. Press the button 0LVFHOODQHRXVand select 6HU Miscellaneous button:
YLFHZLQGRZ.

xx0100000194

2. Select Restart from the File menu.

3. Enter the numbers: 2_5_8 (the fifth function key
changes to P-START)
4. Press 367$57.
The system will reboot, reinstall RAPID and its
auto-loaded modules, and return to the Welcome
window as shown in thefigure in section +RZWR
VHOHFWV\VWHP on page 169.

170 A 3HAC 021333-001

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3.7.9 How to perform a Restart

;67$57FKDQJH An X-start will exit the running system, store system data on the mass storage memory, and
DFWLYHFRQWUROOHU then execute the BootImage to display the Start window. Any system stored in the mass stor-
V\VWHP age memory may then be selected as described in section +RZWRVHOHFWV\VWHP on page 169.
When performing an X-Start all stored system data will be restored (similar to performing a
warm start).

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Press the button 0LVFHOODQHRXVand select 6HU Miscellaneous button:
YLFH window.

xx0100000194

2. Select 5HVWDUWfrom the )LOH menu.

3. Enter the numbers: 1_5_9 (the fifth function key
changes to X-START)
4. Press ;67$57.
The system will reboot and return to the Start win-
dow as shown in the figure in section 6WDUWZLQ
GRZ on page 162.

,67$57VWDUWLQ An I-start can be done if "Use Query Mode at System Boot" was selected when creating the
4XHU\PRGH running system in RobInstall (see section &KDQJHRSWLRQVRUV\VWHPSDFNUHYLVLRQ on page
153). An I-Start will restart the current system and give the opportunity to set some values at
start-up, e.g. language, IRB type (within the same model) or options (see section +RZWR6WDUW
LQ4XHU\0RGH on page 173).

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Press the button 0LVFHOODQHRXV and select6HUYLFH Miscellaneous button:
window.

xx0100000194

2. Select 5HVWDUWfrom the )LOH menu.

3. Enter the numbers: 1_4_7 (the fifth function key
changes to I-START).
4. Press ,67$57.
The system will start to reboot and will be installed
with the system configured as defined in RobInstall.
For more information on the different modes, con-
tinue to section +RZWR6WDUWLQ4XHU\0RGH on page
173.

3HAC 021333-001 A 171

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.7.9 How to perform a Restart

&67$57&ROG When executing a C-Start, the system exits the running system and deletes it from the mass
VWDUWGHOHWHWKH storage memory. The BootImage is then executed and the Start window as shown in the figure
DFWLYHV\VWHP in section 6WDUWZLQGRZ on page 162 is displayed.

Use C-start with caution. Since it deletes the current system, it should not be used to just
switch between installed systems. For this purpose, use X-Start (see section ;67$57FKDQJH
DFWLYHFRQWUROOHUV\VWHP on page 171).

It will take quite some time to implement a Cold start. Just wait until the robot shows the Start
window. When the Start window is shown, a new system can be selected if available in the
mass storage memory (see section 6\VWHPVHOHFWLRQZLQGRZ on page 169) or a new system can
be downloaded and started (see section 7UDQVIHU5RERW&RQWUROOHU6\VWHPXVLQJ(WKHUQHWFRQ
QHFWLRQ on page 155 or7UDQVIHU5RERW&RQWUROOHU6\VWHPXVLQJIORSS\GLVNV on page 158).
Do not touch any key, joystick, enable device, or emergency stop during the cold start until
the Start window is shown as in the figure in section 6WDUWZLQGRZ on page 162.

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Press the button 0LVFHOODQHRXV and select6HUYLFH Miscellaneous button:
window.

xx0100000194

2. Select 5HVWDUWfrom the )LOH menu.

3. Enter the numbers: 1_3_4_6_7_9 (the fifth function
key changes to C-START)
4. Press &67$57.

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3.7.10 How to Start in Query Mode

+RZWR6WDUWLQ4XHU\0RGH

3UHFRQGLWLRQV ,I"Use Query Mode at System Boot" was selected when creating the system in RobInstall
IRUVHOHFWLQJ (see section &KDQJHRSWLRQVRUV\VWHPSDFNUHYLVLRQ on page 153), it is possible to set some
4XHU\0RGHVWDUW values, e.g. language, IRB type (within the same model) or options, at the first start-up of the
system, using a C-Start (see section &67$57&ROGVWDUWGHOHWHWKHDFWLYHV\VWHP on page
172), or later on when performing an I-Start (see section ,67$57VWDUWLQ4XHU\PRGH on
page 171) .

7\SHVRI4XHU\ The first question from the system is which Query Mode to start. Depending on your needs,
0RGH you should select one of the following three:
• Silent Mode, pushbutton 6LOHQW. If Silent Mode is selected, the operating system will
be installed with the system configured as defined in RobInstall.
• Easy Query Mode, pushbutton (DV\4XHU\. In Easy Query Mode you can change
language, remove selected options and select service or standard mode (see section
"Easy Query Mode" below).
• Query Mode, pushbutton 4XHU\. In Query Mode you can, as well as the things in
Easy Query, select DC-link, change Robot type (within the same family) and for IRB
7600/6600/6650, select balancing device (see section "Query Mode" below).

(DV\4XHU\0RGH If Easy Query was chosen as start-up query mode, the following steps will be required to start
the system:

6WHS $FWLRQ ,OOXVWUDWLRQ,QIR

1. Select Service/Standard motion param. Choose
between standard or service motion parameters (push-
button 6WDQG/ pushbutton 6HUYLFH).
2. Choose TP Language. If there was another language
than English selected in RobInstall (see section
&KDQJHRSWLRQVRUV\VWHPSDFNUHYLVLRQ on page 153),
it will be possible to choose the language (pushbutton
(QJOLVK/pushbutton 2WKHU).
3. Install xxxx. For every option that was selected in Rob-
Install (see section &KDQJHRSWLRQVRUV\VWHPSDFN
UHYLVLRQ on page 153) it is now possible to select <HV
to keep the option, or 1R to remove it from the system.

4XHU\0RGH If Query Mode was chosen as start-up query mode, the following steps will be required to
start the system:

6WHS $FWLRQ ,OOXVWUDWLRQLQIR

1. Select Service/Standard motion param. See section
(DV\4XHU\0RGH on page 173, step 1.
2. Choose TP Language. See section (DV\4XHU\0RGH
on page 173, step 2.

3HAC 021333-001 A 173

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.7.10 How to Start in Query Mode

6WHS $FWLRQ ,OOXVWUDWLRQLQIR

3. Select external axes config.
• Pushbutton/Function: No ext= No external
axes are used
• Pushbutton/Function: DCXX= Select external
axes
• Pushbutton/Function: Extaxdc= Select exter-
nal axes in drive cabinet
You can find the article number of the DC-link used on
the unit inside the controller, then use the table &RQILJ
XUDWLRQ,' on page 174 to find out the configuration ID
for that DC-link.
4. Select xxxx model. Choose Robot model type within in
the same family, e.g. 1400, 6400 etc. If there are more
than three options, press pushbutton 6&$1 to view
them.
5. Install xxxx. See section (DV\4XHU\0RGH on page
173, step 3.

&RQILJXUDWLRQ,' You can find the article number of the DC-link used on the unit inside the controller, then use
the table below to find out the configuration ID for that DC-link.

7\SH $UWQR &RQILJ,' 'HVFULSWLRQ

DSQC 345A 3HAB 8101-1 DC0 DC-link
DSQC 345B 3HAB 8101-2 DC1 DC-link
DSQC 345C 3HAB 8101-3 DC2 DC-link
DSQC 345D 3HAB 8101-4 DC3 DC-link, step down
DSQC 346B 3HAB 8101-6 BAD Drive unit, 3-axes
DSQC 346C 3HAB 8101-7 CCB Drive unit, 3-axes
DSQC 346G 3HAB 8101-8 GT Drive unit, 2-axes
DSQC 358C 3HAB 8101-10 DC2T DC-link + single drive unit
DSQC 346E 3HAB 8101-11 ECB Drive unit, 3-axes
DSQC 358E 3HAB 8101-12 DC2C DC-link + single drive unit
DSQC 346U 3HAB 8101-13 GU Drive unit, 2-axes
DSQC 345E 3HAB 8101-14 DC4 DC-link
DSQC 358F 3HAB 8101-15 DC4C DC-link + single drive unit
DSQC 358G 3HAB 8101-16 DC4U DC-link + single drive unit
DSQC 546A 3HAB 8101-18 AC570 Drive unit
DSQC 545A 3HAB 8101-19 DC570 Rectifier

174 A 3HAC 021333-001

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3.8.1 Media pool in the PC

6\VWHPGLUHFWRU\VWUXFWXUH

0HGLDSRROLQWKH3&

'LUHFWRU\ All RobotWare System Packages and Option Packages are stored in a media pool directory
(folder) as shown in the table below.
Two revisions of the same system package may exist in the pool. By default, after having
installed RobInstall, a directory "MediaPool" will be found in the directory Program
Files\ABB Robotics\, and will also be the current one. However any directory in the structure
can be set up as the current media pool in the Preference window (see section 5RE,QVWDOO
SUHIHUHQFHV on page 160).

xx0100000259

$UWQRIROGHUQDPH 'HVFULSWLRQ
3HAC6811-1.00 RobotWare System Pack 3HAC6811-1, rev 00
3HAC6811-1.02 RobotWare System Pack 3HAC6811-1, rev 02
3HEAxxxx-1.01 External option program 3HEAxxxx-1, rev 01
XYZaaaa-1.00 OEM customer external option program XYZaaaa-1, rev 00

1DPLQJFRQYHQ Each package is stored in a directory, the name of which is an article number ending with the
WLRQV sub-number and with the revision number as shown in the table above. All the system packs
and option packs in one media pool must have the correct revision numbers in their directory
names. Thus a later revision can be loaded into the program pool, to be added to the old one,
without changing the article number.

3HAC 021333-001 A 175

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.8.2 System pool in the PC

6\VWHPSRROLQWKH3&

'LUHFWRU\ All systems created with the RobInstall will be stored in a system pool. The default name of
such a system pool is "system" as shown below. Each system stored in the system pool is a
directory with the name of the system as shown in the table below.
By default, after installing RobInstall, a directory "system" will be found in Program
Files\ABB Robotics\ and will also be the current one. However any directory in the structure
can be set up as the current system directory in the Create New System window or Select
System window.

Directory view Folder "System 1"

xx0100000260

xx0100000261

)LOHV\VWHP The system directory must hold these files and directories to allow software installation:
UHTXLUHPHQWV • key.id (encrypted key file for the actual controller)
• program.id (file with paths to selected programs in the media pool)
• A V\VSDU directory containing .cfg files to be included in the software installation pro-
cedure. All system parameter files, included when creating a system with RobInstall,
are stored in this syspar directory as shown in the table in section "Directory".
• A directory called Home. In this home directory the user can include any file or files,
which should be downloaded to the controller together with the operating system.
Such files will then be placed in the home directory of the system in the controller.

176 A 3HAC 021333-001

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3.8.3 File structure in the robot controller mass storage memory

)LOHVWUXFWXUHLQWKHURERWFRQWUROOHUPDVVVWRUDJHPHPRU\

)LOHVLQURRWGLUHF The root directory of the mass storage memory is called hd0a. This includes several compo-
WRU\KGD nents:

)LOHQDPH 'HVFULSWLRQ
E.g. 3HAC6811-1.00 Control system package, named as an article number
bin BootImage code
BootRom.sys System configuration and description file for the mass storage mem-
ory
MC.cfg Network configuration for the main computer
ctrl.bin Holds e.g. revolution counter values
system.dir Holds information on the current system
system directories Different systems stored in the mass storage memory

'LUHFWRULHVDQG Each system directory holds a number of subdirectories, defining for instance language,
VXEGLUHFWRULHV options, robots, etc.

+RPHGLUHFWRU\ The system directory is the "home" directory for the system. When using the address "home:"
in the RAPID program, this directory will be addressed.

%LQVXEGLUHF The subdirectory bin, containing the storage area for all system data, e.g. at power break. This
WRU\ means that at warm start, in addition to restoring the operating system from the control system
package, all system data is restored from this directory and reloaded into the working mem-
ory.

1HYHUFKDQJH Never delete or change the \bin or BootRom.sys directories in the root directory. If this is
WKHVHGLUHFWRULHV done, the controller cannot be restarted and it will be impossible to use the mass storage
memory.

3HAC 021333-001 A 177

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.8.4 Preparation of S4Cplus software to be installed

3UHSDUDWLRQRI6&SOXVVRIWZDUHWREHLQVWDOOHG

,OOXVWUDWLRQ
Media pool System pool

System Pack in Ext Option in Created files My system

/3HAC6811-1.nn /3HEAxxxx-1.nn key.id /system_n
*.* signature no *.* relkey.txt program.id key.id
program.id
keystr.txt
/syspar
External option from
*.cfg
disk or CD-ROM

System Pack from

RobotWare CD-ROM Inserted key strings
are saved in keystr.txt
RobotWare keystrings define the options
to be included from the System Pack
they belong to and Ext opt keystrings define
added external option packages.
All keys must have the same serial number.
xx0100000262

)LOHVWREHSUH The list details what happens during preparation:

SDUHG • RobInstall creates a file named .H\LG from the key strings specifying the options to
be installed from the System Pack and the external option programs to be installed.
• Unless deselected in RobInstall, the latest revision of the System Pack and External
Option Programs is selected as default (see section &KDQJHRSWLRQVRUV\VWHPSDFN
UHYLVLRQ on page 153).
• These are copied from the media pool and concatenated into one target file that also
holds the key.id and the syspar directory. This may then be downloaded to the control-
ler via Ethernet or a set of diskettes. The target file is temporarily stored in the system
directory before downloading or creating diskettes.

178 A 3HAC 021333-001

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3.8.5 Handling mass memory storage capacity

+DQGOLQJPDVVPHPRU\VWRUDJHFDSDFLW\

*HQHUDO In some cases it is very important that there is enough free space in the mass storage memory,
before attempting to download new system software. How to check its capacity, and if
required increase it, is detailed below.
A manual check on the free space can be done in one of the following ways:

&KHFNLQJVWRUDJH  Press the button 0LVFHOODQHRXVto select Service window .

FDSDFLW\IURPWKH  Select Storage Capacity from the System Info menu. The Mass Storage Memory
7HDFK3HQGDQW is called KGD.
8QLW

&KHFNLQJVWRUDJH  Connect a console to the MC/CONSOLE outlet on the controller and execute the command
FDSDFLW\WKURXJK dosFsShow .
FRQQHFWLRQWRWKH
0&&2162/(
SRUW

There should always be at least 25 Mb free disk space on the controller mass storage memory
before attempting to download a new system. For information on how to increase storage
capacity, see below!

,QFUHDVLQJVWRU If the capacity of the mass storage memory is less than 25 Mb when a new controller system
DJHFDSDFLW\ is to be downloaded, storage memory must be released by removing old systems from the
mass storage memory. This can be done in one of the following ways:
 Boot up on the system you would like to remove and then make a C-START (see section
&67$57&ROGVWDUWGHOHWHWKHDFWLYHV\VWHP on page 172).
 Use the FileManager in the Teach Pendant Unit, see User’s Guide - File Manager, for more
information on how to use the FileManager.
 Use a third-party "ftp" client (like FTPVoyager supplied on the RobotWare CD).

Removing systems using the FileManager or FTP-client may be hazardous since the \bin and
BootRom.sys directories must be kept intact.
Proceed with the utmost care to avoid accidentally removing such files or directories!

3HAC 021333-001 A 179

,QVWDOODWLRQDQGFRPPLVVLRQLQJ
3.8.5 Handling mass memory storage capacity

180 A 3HAC 021333-001

 0DLQWHQDQFH
4.0.1 Introduction

0DLQWHQDQFH
,QWURGXFWLRQ

*HQHUDO This chapter contains information on how to maintain the equipment described, i.e. how to
perform the preventive maintenance activities specified in the maintenance schedule for the
same equipment.

3HAC 021333-001 A 181

0DLQWHQDQFH
4.1.1 Maintenance schedule, controller S4CPlus

0DLQWHQDQFHVFKHGXOH

0DLQWHQDQFHVFKHGXOHFRQWUROOHU6&3OXV

*HQHUDO The robot controller must be maintained at regular intervals to ensure its function. The main-
tenance activities and their respective intervals are specified in the table below:

,QWHUYDOV

0DLQWHQDQFH
(TXLSPHQW ,QWHUYDO 1RWH 'HWDLOHGLQVHFWLRQ
DFWLYLW\
Inspection Controller cabinet 6 mths ,QVSHFWLRQRIFRQWUROOHU
FDELQHW on page 183
Cleaning Controller cabinet &OHDQLQJRIFRQWUROOHU
FDELQHW on page 184
Cleaning Air filter &OHDQLQJDLUILOWHU on
page 185
Replacement Air filter 4,000 h/24 mths 1 5HSODFHPHQWRIDLUILO
WHU on page 196
Replacement Battery unit 12,000 h/36 mths 1 5HSODFHPHQWRIEDWWHU\
XQLW on page 193
Replacement System fan unit 36 mths 5HSODFHPHQWRIGULYH
V\VWHPIDQXQLW on
page 190
Replacement Fan unit in com- 36 mths
puter system
Replacement CMOS battery 72 mths 5HSODFHPHQWRI&026
EDWWHU\ on page 187

1)
Hours denotes operational time whereas months denotes the actual calender time.

182 A 3HAC 021333-001

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4.2.1 Inspection of controller cabinet

,QVSHFWLRQDFWLYLWLHV

,QVSHFWLRQRIFRQWUROOHUFDELQHW

,QVSHFWLRQ The procedure below details how to inspect the controller cabinet.

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Inspect the cabinet interior to make sure Replace any faulty seals as
there is no contamination. required.
If any contamination is found, the cabinet
interior must be cleaned and all gaskets and
seals to the cabinet inspected.
2. Inspect all sealing joints and cable glands to
make sure they are airtight in order to prevent
dust and dirt from being sucked into the cab-
inet.
3. Inspect connectors and cabling to make sure
they are securely fastened and cabling is not
damaged.
4. Inspect any air filters to make sure they are Clean any contaminated filters as
clean. detailed in section &OHDQLQJDLUILOWHU
on page 185.
5. Inspect any fans to make sure they function Replace any malfunctioning fans as
correctly. detailed in their respective sections.

3HAC 021333-001 A 183

0DLQWHQDQFH
4.3.1 Cleaning of controller cabinet

&OHDQLQJDFWLYLWLHV

&OHDQLQJRIFRQWUROOHUFDELQHW

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Vacuum cleaner ESD Protected
Cleaning agent, exte- If necessary, use rag with e.g. alco-
rior cleaning hol
8VH(6'3URWHFWLRQ

,QWHUQDOFOHDQLQJ The procedure below details how to clean the interior of the controller cabinet.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Clean the cabinet interior with a vac-
uum cleaner if necessary.
2. If the cabinet is equipped with heat If required, remove any heat exchangers
exchangers, it is of the utmost impor- before cleaning as detailed in the Repair
tance that these are cleaned. Manual.
Heat exchangers are normally found:
• on the rear of power supplies
• on the rear of computer mod-
ules
• on drive units

'R
VDQGGRQ
WV The section below specifies some special considerations when cleaning the controller cabinet.

$OZD\V • use ESD Protection

• use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life of paintwork, rust inhibitors, signs, or labels!
• check that all protective covers are fitted to the controller before cleaning!

1HYHU • remove any covers or other protective devices before cleaning the controller!
• use any cleaning agents, e.g. compressed air or solvents, other than those specified
above!
• spray with a high pressure cleaner!

184 A 3HAC 021333-001

 0DLQWHQDQFH
4.3.2 Cleaning air filter

&OHDQLQJDLUILOWHU

/RFDWLRQRIDLU The air filter is located as shown in the figure below:

ILOWHU
B C

A D E
xx0200000002

A Air filter
B I/O and gateway units
C Power supply unit
D Drive system
E Computer system

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Cleaning agent Water 30-40°C with cleansing liquid or
detergent
Compressed air

6DIHW\LQIRU Read the safety information below before cleaning the air filter.
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

3HAC 021333-001 A 185

0DLQWHQDQFH
4.3.2 Cleaning air filter

&OHDQLQJ The procedure below details how to clean the air filter.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 185!
2. Clean with the rough surface (on the clean air side)
turned inwards.
3. Clean the filter three or four times.
4. Allow the filter to dry in one of these ways: Do not wring the filter out!
• Lying flat on a flat surface
• Blow dry with compressed air from the clean-
air side.

186 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.1 Replacement of CMOS battery

5HSODFHPHQWDFWLYLWLHV

5HSODFHPHQWRI&026EDWWHU\

/RFDWLRQRI The CMOS battery is located on the main computer in the computer system of the cabinet.
&026EDWWHU\

X
G
A B

G-G

X X-X
xx0400000777

A Computer system
B CMOS battery located on the main computer DSQC 500
C Attachment screws, cover

5HTXLUHG
HTXLSPHQW
(TXLSPHQW $UWQR 1RWH
CMOS battery 3HAC 14441-9 DIP LITHIUM BUTTON-CELL 3V NO-CR2032
Same battery on DSQC 500 and DSQC 540.

6DIHW\LQIRU Read the safety information below before replacing the CMOS battery.
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!

3HAC 021333-001 A 187

0DLQWHQDQFH
4.4.1 Replacement of CMOS battery

- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

5HSODFHPHQW The procedure below details how to replace the CMOS battery.
&026EDWWHU\

6WHS $FWLRQ 1RWH

1. Read the 6DIHW\LQIRUPDWLRQ on page 187!
2. Put the computer system in service position. Detailed in section 3XWWLQJWKH
FRPSXWHUV\VWHPLQVHUYLFHSRVL
WLRQ on page 202.
3. Remove the cover from the right side of the Shown in the figure /RFDWLRQRI
computer system by unscrewing the ten DWWDFK &026EDWWHU\ on page 187.
PHQWVFUHZVFRYHU.
4. Disconnect all connectors from the main com-
puter.
5. Remove the main computer by lifting it up from
the computer system.
6. Remove the CMOS battery from the main com-
puter board.

xx0400000778

• A: CMOS battery on main

computer DSQC 500

A
xx0400000781

• A: CMOS battery on main

computer DSQC 540

188 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.1 Replacement of CMOS battery

6WHS $FWLRQ 1RWH

7. Fit the new &026EDWWHU\ to the main computer Art. no. is specified in 5HTXLUHG
board. HTXLSPHQW on page 187.

Caution!

Avoid contamination of the battery during han-

dling! Contamination degrades the battery con-
tact.
8. Refit the main computer to the computer sys-
tem.
9. Reconnect all connectors to the main computer.
10. Refit the cover to the computer system by Shown in the figure /RFDWLRQRI
securing the DWWDFKPHQWVFUHZVFRYHU. &026EDWWHU\ on page 187.
11. Put the computer system back in the regular Detailed in section 3XWWLQJWKH
operation position. FRPSXWHUV\VWHPLQVHUYLFHSRVL
WLRQ on page 202.
12. After restarting the system, the date and time Further information about the ser-
must be set with the TPU: vice window may be found in
1. Press the Miscellaneous key. 8VHU
V*XLGH6HUYLFH7KH6HU
YLFH:LQGRZ.
2. Select 6HUYLFH in the dialog box that
appears. Art. no. for the manual is speci-
fied in section 'RFXPHQWUHIHU
3. Press Enter to open the Service window. HQFHVin the 3URGXFWPDQXDO
4. Choose 9LHZ'DWH 7LPH. UHIHUHQFHLQIRUPDWLRQ.
5. Select 'DWHor 7LPH using the arrow
keys.
6. Change the date or time using the func-
tion keys (< or >).
7. Choose 2. to confirm.

3HAC 021333-001 A 189

0DLQWHQDQFH
4.4.2 Replacement of drive system fan unit

5HSODFHPHQWRIGULYHV\VWHPIDQXQLW

/RFDWLRQRIGULYH The fan unit is located as shown in the figure below.

V\VWHPIDQXQLW

xx0200000007

A Drive units
B Bleeder resistor unit
C Fan unit
D Rectifier (drive unit)
E Power supply unit

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Fan unit, 4 fans 3HAC 12924-1
Other tools and procedures may These procedures include
be required. See references to references to the tools
these procedures in the step-by- required.
step instructions below.

190 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.2 Replacement of drive system fan unit

5HPRYDOGULYH The procedure below details how to remove the fan unit.
V\VWHPIDQXQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Remove the bleeder Detailed in procedure 5HPRYDOEOHHGHUUHVLVWRU on page
resistor unit. 208.
2. Disconnect the cable
(see position 1 in the
figure).

  


xx0200000008

3. Pull the back of the

fan unit upwards to
free it and then tip it
out of the enclosure
(see position 2 in the
figure ).

5HILWWLQJGULYH The procedure below details how to refit the fan unit.
V\VWHPIDQXQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

3HAC 021333-001 A 191

0DLQWHQDQFH
4.4.2 Replacement of drive system fan unit

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Fit the GULYHV\VWHPIDQXQLW into position and Art. no. is specified in
secure it (see position 2 in the figure above). 5HTXLUHGHTXLSPHQW on
page 190!
2. Reconnect the cable disconnected during
removal (see position 1 in the figure above).
3. Refit the bleeder resistor unit. Detailed in procedure
5HILWWLQJEOHHGHUUHVLV
WRU on page 209.

192 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.3 Replacement of battery unit

5HSODFHPHQWRIEDWWHU\XQLW

/RFDWLRQRI The battery unit is located at the bottom of the controller.

EDWWHU\XQLW

A
xx0200000103

A Battery unit

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Battery unit 3HAC 5393-2 To be replaced as a complete
unit
Other tools and procedures These procedures include ref-
may be required. See refer- erences to the tools required.
ences to these procedures in
the step-by-step instructions
below.

3HAC 021333-001 A 193

0DLQWHQDQFH
4.4.3 Replacement of battery unit

5HPRYDOEDWWHU\ The procedure below details how to remove the battery unit.
XQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Remove the battery
unit by unscrewing its
attachment screws (1).

X1 X1 X1

X1

X2 X2 X2 X2

X3

xx0200000004

2. Pull the battery unit out

(2).
3. Disconnect the three
cables from the battery
unit (3).

xx0200000005

194 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.3 Replacement of battery unit

5HILWWLQJEDWWHU\ The procedure below details how to refit the battery unit.
XQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Place the EDWWHU\XQLW close to its posi- Art. no. specified in 5HTXLUHGHTXLSPHQW
tion. on page 193!
See figure /RFDWLRQRIEDWWHU\XQLW on page
193!
2. Reconnect the cables (3) and push the See illustration xx0200000005 above!
unit into position.
1RWH Make sure the connectors are
properly attached to the battery and the
board.
3. Secure the battery unit with the attach- See illustration xx0200000004 above!
ment screws (1).

3HAC 021333-001 A 195

0DLQWHQDQFH
4.4.4 Replacement of air filter

5HSODFHPHQWRIDLUILOWHU

/RFDWLRQRIDLU The air filter is located in the air filter magazine in the front hatch.
ILOWHU

A A
xx0200000102

A Air filter magazine

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Air filter 3HAC 5295-1
Other tools and procedures may These procedures
be required. See references to include references to the
these procedures in the step-by- tools required.
step instructions below.

6DIHW\LQIRU Read the safety information below before replacing the air filter!
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

196 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.4 Replacement of air filter

5HPRYDODLUILOWHU The procedure below details how to remove the air filter.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ
on page 196!
2. Open the bottom of the air
filter magazine as shown in
the figure.

xx0200000001

3. Unlock the lower springs.

Lower the magazine and
remove it.
4. Remove the old filter by
releasing the lock shackle
and lifting it.
Note! If the air filter is not
seriously contaminated, it 
may be cleaned and refitted.
The procedure for this is
detailed in section "Cleaning
the air filter, controller" in the
Maintenance Manual. 

xx0200000003

5HILWWLQJDLUILOWHU The procedure below details how to refit the air filter.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ
on page 196!
2. Fit the DLUILOWHU in the maga- Art. no. is specified in 5HTXLUHGHTXLSPHQW on page
zine. 196!

3HAC 021333-001 A 197

0DLQWHQDQFH
4.4.4 Replacement of air filter

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

3. Fit the spring at the top of
the air filter magazine into
the cabinet door and push
upwards inwards.
Push until the lower springs
snap into the cabinet door.

xx0200000006

198 A 3HAC 021333-001

 0DLQWHQDQFH
4.4.5 Replacement of fan unit in computer system

5HSODFHPHQWRIIDQXQLWLQFRPSXWHUV\VWHP

/RFDWLRQRIIDQ The fan unit is located in the computer system as shown in the figure below.
XQLW

D
C
X G B
A G
G-G

X
X-X
xx0400000780

A Computer system
B Fan unit with grating
C Heat exchanger
D Attachment screws, cover

5HTXLUHG
HTXLSPHQW
(TXLSPHQW $UWQR 1RWH
Fan with receptacle 3HAC 6658-1 Does not include grating.
Fan with receptacle, incl. grating 3HAC 15415-1
Grating 21580132-176

6DIHW\LQIRU Read the safety information below before replacing the fan unit.
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!

3HAC 021333-001 A 199

0DLQWHQDQFH
4.4.5 Replacement of fan unit in computer system

- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

5HPRYDOIDQXQLW The procedure below details how to remove the fan unit.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 199.
2. Put the computer unit in service position. Detailed in section 3XWWLQJ
WKHFRPSXWHUV\VWHPLQVHU
YLFHSRVLWLRQ on page 202.
3. Remove the KHDWH[FKDQJHU from the computer Shown in the figure /RFDWLRQ
system. RIIDQXQLW on page 199.
4. Remove the cover from the right side of the com- Shown in the figure /RFDWLRQ
puter system by unscrewing the ten DWWDFKPHQW RIIDQXQLW on page 199.
VFUHZVFRYHU.
5. Disconnect the connector of the fan.
6. Open the reusable strap to loosen the cable of the
fan from the other cabling.
7. Remove the fan by removing its four attachment
screws.
8. Remove the grating from the fan in order to fit it to
the new fan.

5HILWWLQJIDQXQLW The procedure below details how to refit the fan unit.

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on page 199.
2. Fit the grating to the new IDQXQLW. Art. no. is specified in
5HTXLUHGHTXLSPHQW on
page 199.
3. Fit the fan unit to the computer system.
1RWH Make sure to fit the fan in the correct direc-
tion. The arrows on the fan should point out from the
cabinet and the grating face inside the cabinet.
4. Secure the fan unit with its four attachment screws.
5. Reconnect the connector of the fan.
6. Fasten the cable with the reusable strap to the the Shown in the figure /RFDWLRQ
other cabling. RIIDQXQLW on page 199.
7. Refit the cover to the side of the computer system
with its ten DWWDFKPHQWVFUHZVFRYHU.
8. Refit the KHDWH[FKDQJHU to the computer system. Shown in the figure /RFDWLRQ
RIIDQXQLW on page 199.
9. Put the computer system back in regular operation
position.

200 A 3HAC 021333-001

 5HSDLU
5.0.1 Introduction

5HSDLU
,QWURGXFWLRQ

'HILQLWLRQV This chapter details all repair activities recommended for the controller.
It is made up of separate units, each detailing a specific repair activity, e.g. Removal or Refit-
ting of a certain component in the controller. Each unit contains all information required to
perform the activity, e.g. spare parts numbers, required special tools and materials.
The chapter is divided into the following sections:
• Removal instructions for all components.
• Refitting instructions for all components.
• Remaining instructions.

3HAC 021333-001 A 201

5HSDLU
5.1.1 Putting the computer system in service position

&RPSOHWHFRQWUROOHUFDELQHW

3XWWLQJWKHFRPSXWHUV\VWHPLQVHUYLFHSRVLWLRQ

/RFDWLRQRIFRP The computer system is located as shown in the figure below.

SXWHUV\VWHP

xx0200000105

A Computer system

2SHQLQJ The procedure below details how to pull the computer system out of the cabinet, in order to
put it in service position.

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Make sure the ESD
wrist-band is worn and
connected to ground.

202 A 3HAC 021333-001

 5HSDLU
5.1.1 Putting the computer system in service position

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

2. Disconnect all connec-
tors/cables and make
sure they do not
obstruct pulling the
computer system out.
3. Unscrew the transport
locks in both corners of
the computer system.
 
This is done by turning
the screw two turns
(see position 1 in the
figure) and pushing the
lock washers towards
the screw (see position
xx0200000016
2).
4. Lift the two handles and
push them together to 
release the computer
system (see position 1
in the figure).

xx0200000017

5. Push the locking device See the figure above!

on the front of the com-
puter system to the
right (see position 2 in
the figure).
6. Pull the computer sys-
tem out of the cabinet
until locked in its end
position. Then swing it
to the left as shown in
the figure.

xx0200000018

3HAC 021333-001 A 203

5HSDLU
5.1.1 Putting the computer system in service position

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

7. If work is to be per-
formed on the com-
puter system while in
the service position, it
must be locked in this
position. This is done
by placing the puck
(located on the lower
left side) on the metal
bar. Alternatively, the
computer system may
be removed by lifting it
straight up and placing
it on a work bench.

&ORVLQJ The procedure below details how to put the computer system back into regular operation
position.

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Swing the computer system back into position See the figure above!
and secure it. Also see the procedure above!

204 A 3HAC 021333-001

 5HSDLU
5.1.2 Replacement of I/O and gateway units

5HSODFHPHQWRI,2DQGJDWHZD\XQLWV

/RFDWLRQRI,2 The I/O and gateway units are located as shown in the figure below.
DQGJDWHZD\XQLWV
A

xx0200000009

A I/O and gateway units located beneath the top cover of the cabinet
B Four available slots for I/O and gateway units

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF $UWQR 1RWH
Digital 120 VAC I/O 3HAB 7231-1 DSQC 320
AD Combi I/O 3HAC 17971-1 DSQC 327A
Digital 24 VDC I/O 3HAC 17970-1 DSQC 328A

3HAC 021333-001 A 205

5HSDLU
5.1.2 Replacement of I/O and gateway units

(TXLSPHQWHWF $UWQR 1RWH

Digital I/O with relays 3HAC 17973-1 DSQC 332A
Gateway for Allen-Bradley, RIO 3HNE 00025-1 DSQC 350
Gateway for Interbus-S 3HNE 00006-1 DSQC 351
Gateway for Profibus DP, slave unit 3HNE 00009-1 DSQC 352
Circuit board ENC-01 3HNE 00065-1 DSQC 354
Analog I/O 3HNE 00554-1 DSQC 355
Queue Tracker 3HNE 01586-1 DSQC 377

5HPRYDOXQLWV The procedure below details how to remove an I/O or gateway board.

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Disconnect any connectors from The actual number of connectors varies depend-
the unit. Note which connector ing on the type of unit.
goes where, to facilitate reas-
sembly.
2. Lift the unit until the upper claw,
that holds the unit to the rail, is
released. Use:
• a screwdriver when
replacing I/O units (posi-  D D
tion 2a in the figure to the
right).
• by hand when replacing
a gateway unit (position
2b in the figure to the
right).

 E E

xx0200000010

3. With the upper claw released, tip

the unit away from the mounting
rail and remove it (positions 3a
and 3b in the figure above).

206 A 3HAC 021333-001

 5HSDLU
5.1.2 Replacement of I/O and gateway units

5HILWWLQJXQLWV The procedure below details how to refit an I/O or gateway board.

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Hook the unit back onto the mounting rail and snap it gently
in position.
2. Reconnect all connectors disconnected during removal.

3HAC 021333-001 A 207

5HSDLU
5.1.3 Replacement of bleeder resistor

5HSODFHPHQWRIEOHHGHUUHVLVWRU

/RFDWLRQRI The bleeder resistor is located behind the drive units, as shown in the figure below.
EOHHGHUUHVLVWRU

xx0200000007

A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Bleeder resistor 3HAC 4560-5

5HPRYDOEOHHGHU The procedure below details how to remove the bleeder resistor.
UHVLVWRU

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!

208 A 3HAC 021333-001

 5HSDLU
5.1.3 Replacement of bleeder resistor

- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Swing the power supply unit Detailed in section 5HPRYDOSRZHUVXSSO\XQLW on
out of the way. page 219.
2. Remove the drive units. Detailed in section 5HPRYDOGULYHXQLWV on page 217.
3. Disconnect the cable
secured on top of the
bleeder resistor unit (see 
position 1 in the figure). 

xx0200000015

4. Remove the bleeder resistor

unit from the enclosure (see
position 2 in the figure).

5HILWWLQJEOHHGHU The procedure below details how to refit the bleeder resistor.
UHVLVWRU

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Fit the EOHHGHUUHVLVWRU into position Art. no. is specified in 5HTXLUHGHTXLSPHQW
and secure it with the spring. on page 208!
Also see the figure /RFDWLRQRIEOHHGHUUHVLV
WRU on page 208!
2. Secure the cable disconnected dur-
ing disassembly.
3. Refit the drive unit. Detailed in section 5HILWWLQJGULYHXQLWV on
page 218.
4. Swing the power supply unit back Detailed in section 5HILWWLQJSRZHUVXSSO\
into position. XQLW on page 220.

3HAC 021333-001 A 209

5HSDLU
5.1.4 Replacement of mass storage memory

5HSODFHPHQWRIPDVVVWRUDJHPHPRU\

/RFDWLRQRIPDVV The mass storage memory is located in the computer system, which is shown in the figure
VWRUDJHPHPRU\ below.

xx0200000105

A Computer system

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Mass storage memory, 64 MB 3HAC 7519-2
Mass storage memory, 128 MB 3HAC 7519-3
Other tools and procedures may These procedures
be required. See references to include references
these procedures in the step-by- to the tools required.
step instructions below.

6DIHW\LQIRU Read the safety information below before replacing the mass storage memory.
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!

210 A 3HAC 021333-001

 5HSDLU
5.1.4 Replacement of mass storage memory

- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

5HPRYDOPDVV The procedure below details how to remove the mass storage memory.
VWRUDJHPHPRU\

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on
page 210!
2. Put the computer system in the Detailed in section 3XWWLQJWKHFRPSXWHUV\VWHP
service position. LQVHUYLFHSRVLWLRQ on page 202.
3. Remove the cover from the right

side of the computer system by
unscrewing the ten M5 screws
(item 1 in the figure).

 

xx0200000019

4. Disconnect the connectors X1 See figure above!

and X2 from the front of the
mass storage memory (item 2 in
the figure).
5. Remove the mass storage mem- See figure above!
ory by unscrewing its M4 attach-
ment screws as shown in the
figure (items 3 and 4 in the fig-
ure).

5HILWWLQJPDVV The procedure below details how to refit the mass storage memory.
VWRUDJHPHPRU\

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on
page 210!

3HAC 021333-001 A 211

5HSDLU
5.1.4 Replacement of mass storage memory

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

2. Fit the PDVVVWRUDJHPHPRU\ in Art. no. is specified in 5HTXLUHGHTXLSPHQW on
position and secure it with its M4 page 210!
attachment screws (items 3 and
4 in the figure) 

 

xx0200000019

3. Reconnect connectors X1 and See the figure above!

X2 to the front of the mass stor-
age memory (item 2 in the fig-
ure).
4. Refit the cover on the right side See the figure above!
of the computer unit and secure
it with its ten M5 attachment
screws (item 1 in the figure).
5. Put the computer system back Detailed in section 3XWWLQJWKHFRPSXWHUV\VWHP
in the regular operation position. LQVHUYLFHSRVLWLRQ on page 202.

212 A 3HAC 021333-001

 5HSDLU
5.1.5 Replacement of internal cooling fan

5HSODFHPHQWRILQWHUQDOFRROLQJIDQ

/RFDWLRQRI The internal cooling fan is located in the computer system, which is shown in the figure
LQWHUQDOFRROLQJ below.
IDQ

xx0200000105

A Computer system

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Internal cooling fan 3HAC 6655-1 Two fans required
Other tools and procedures These procedures
may be required. See refer- include references to the
ences to these procedures tools required.
in the step-by-step instruc-
tions below.

6DIHW\LQIRU Read the Safety information below before replacing the internal cooling fan.
PDWLRQ

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!

3HAC 021333-001 A 213

5HSDLU
5.1.5 Replacement of internal cooling fan

- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

5HPRYDOLQWHUQDO The procedure below details how to remove the internal cooling fan.
FRROLQJIDQ

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on
page 213.
2. Put the computer system in the Detailed in section 3XWWLQJWKHFRPSXWHUV\VWHP
service position. LQVHUYLFHSRVLWLRQ on page 202.
3. Disconnect the connector E5 or
E6 respectively, depending on
which fan is to be replaced.

D C B

xx0200000020

• A: Upper fan
• B: Lower fan
• C: Locking tabs
• D: Connector E5
• E : Connector E6
4. Remove the LQWHUQDOFRROLQJIDQ See the figure above!
inwards by gently pressing the
locking tabs upwards.

214 A 3HAC 021333-001

 5HSDLU
5.1.5 Replacement of internal cooling fan

5HILWWLQJLQWHUQDO The procedure below details how to refit the internal cooling fan.
FRROLQJIDQ

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Read the 6DIHW\LQIRUPDWLRQ on
page 213.
2. Tip the LQWHUQDOFRROLQJIDQwith Art. no. is specified in 5HTXLUHGHTXLSPHQW on
its top towards the cabinet wall page 213!
and fit it into the hole (see the fig-
ure).

A
xx0200000021

• A: Push direction
3. With the wall between the upper See the figure above!
lock spring hooks, push the fan
unit up and in until the locking
tab snaps to the wall.
4. Reconnect the connector E5 or
E6 respectively, depending on
which fan was replaced.
5. Put the computer system back in Detailed in section 3XWWLQJWKHFRPSXWHUV\VWHP
the regular operation position. LQVHUYLFHSRVLWLRQ on page 202.

3HAC 021333-001 A 215

5HSDLU
5.1.6 Replacement of drive units and rectifier

5HSODFHPHQWRIGULYHXQLWVDQGUHFWLILHU

/RFDWLRQRIGULYH The drive units and rectifier are located as shown in the figure below.
XQLWVDQGUHFWLILHU

xx0200000007

A Drive units
B Bleeder resistor unit
C System fan unit
D Rectifier (drive unit)
E Power supply unit

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Drive unit (rectifier) 3HAB 8101-17 DSQC 545A
Drive unit, axes 1-6 3HAB 8101-18 DSQC 546A
Other tools and procedures may These procedures
be required. See references to include references to
these procedures in the step-by- the tools required.
step instructions below.

216 A 3HAC 021333-001

 5HSDLU
5.1.6 Replacement of drive units and rectifier

5HPRYDOGULYH The procedure below details how to remove the drive units.
XQLWV

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Swing the power supply unit Detailed in section 5HPRYDOSRZHUVXSSO\XQLW on
out of the way. page 219.
2. Disconnect connectors X1
and X2, four connectors each
(see position 1 in the figure).

xx0200000013

3. Remove the power supply See figure above!

bar in front of the drive units
(see position 2 in the figure).
4. Lift the spring to release the
drive unit and pull it slightly
outwards (see position 3 in
the figure).

 
xx0200000014

5. Tip it out and remove it (see See figure above!

position 4 in the figure).

3HAC 021333-001 A 217

5HSDLU
5.1.6 Replacement of drive units and rectifier

5HILWWLQJGULYH The procedure below details how to refit the drive units.
XQLWV

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Fit the unit into position and secure it with the Also see figure above!
spring.
2. Refit the power bar in front of the unit.
3. Reconnect all connectors X1 and X2.
4. Swing the power supply unit back into position. Detailed in section 5HILWWLQJ
SRZHUVXSSO\XQLW on page 220.

218 A 3HAC 021333-001

 5HSDLU
5.1.7 Replacement of power supply unit

5HSODFHPHQWRISRZHUVXSSO\XQLW

/RFDWLRQRISRZHU The power supply unit is located as shown in the figure below.
VXSSO\XQLW

xx0200000011

A Power supply unit locking spring (view from front)

B Power supply unit swung out from the cabinet (view from above)

5HTXLUHG
HTXLSPHQW
(TXLSPHQWHWF 6SDUHSDUWQR $UWQR 1RWH
Power supply unit 3HAB 4297-1 DSQC 506
Other tools and proce- These procedures include
dures may be required. references to the tools
See references to these required.
procedures in the step-by-
step instructions below.

5HPRYDOSRZHU The procedure below details how to remove the power supply unit.
VXSSO\XQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

3HAC 021333-001 A 219

5HSDLU
5.1.7 Replacement of power supply unit

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Push the SRZHUVXSSO\XQLWORFNLQJ Shown in the figure /RFDWLRQRISRZHUVXSSO\
VSULQJ down to release the power XQLW on page 219!
supply unit.
2. Swing the unit out of the cabinet. Shown in the figure /RFDWLRQRISRZHUVXSSO\
XQLW on page 219!
3. Remove the cable straps on top of
the power supply unit (see position 1
in the figure).

xx0200000012

4. Disconnect the cables at the back of

the unit (see position 2 in the figure).
5. Remove the screw (see position 3 in
the figure).
6. Lift the unit straight up to release it
from the hooks and remove it out-
wards (see position 4 in the figure).

5HILWWLQJSRZHU The procedure below details how to refit the power supply unit.
VXSSO\XQLW

:DUQLQJ
Please observe the following before commencing any work on the controller or units con-
nected to the controller:
- Turn off all electric power supplies to the cabinet!
- Many components inside the cabinet or inside any external units are sensitive to ESD (Elec-
troStatic Discharge) and will be destroyed if subjected to it!
- Before handling, make sure you are grounded through a special ESD wrist bracelet or sim-
ilar. Many module and unit fronts are fitted with a special ESD protection button for connec-
tion of the bracelet. Use it!

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

1. Fit the SRZHUVXSSO\XQLW into position onto its Art. no. is specified in 5HTXLUHG
hooks and secure it with the attachment screw HTXLSPHQW on page 219!
(see position 3 and 4 in figure in the section
Removal).
2. Reconnect all connectors disconnected during
removal (see position 2 in figure).

220 A 3HAC 021333-001

 5HSDLU
5.1.7 Replacement of power supply unit

6WHS $FWLRQ 1RWH,OOXVWUDWLRQ

3. Secure the cables on top of the unit with new
cable straps (see position 1 in figure).
4. Swing the unit back into the cabinet and secure it
with the locking spring.

3HAC 021333-001 A 221

5HSDLU
5.1.7 Replacement of power supply unit

222 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.1 Introduction

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
,QWURGXFWLRQ

2YHUYLHZ When the controller is used in a robot system with a non-ABB manipulator, the system
requires configuration and tuning as detailed in this chapter.
The chapter is divided into following sections:
• .LQHPDWLFPRGHOV on page 224. Describes the different built-in kinematic models in
the controller. An appropriate model must be chosen for the current robot system,
before the system can be configured and tuned.
• &RQILJXUDWLRQ on page 241. Describes the parameters in the configuration files. Some
of the parameters must be set (minimal configuration) while others are optional.
• 7XQLQJ on page 285. Describes how to adjust certain parameters in order to achieve
the best possible motion performance in the robot system.
• )LOHKDQGOLQJFRQILJXUDWLRQDQGHUURUPDQDJHPHQW on page 304. Describes how to
work with the configuration files and how to find errors, if any.

3UHUHTXLVLWHV
Before configuration and tuning of the controller, the integrator must have knowledge of:
• controller configuration and setup.
• drive, motor and position feedback device.
• Test Signal Viewer or other motion data collection and plotting software. The Test Sig-
nal Viewer is delivered with the RobotWare CD-ROM. More information about the soft-
ware can be found in the enclosed documentation.
• mechanical and dynamic properties of the controlled mechanism.

3HAC 021333-001 A 223

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.1 Introduction

.LQHPDWLFPRGHOV

,QWURGXFWLRQ

2YHUYLHZ This section describes the different kinematic models that are available in the controller. This
section is also a guideline for choosing the appropiate model for the current robot system.

7HPSODWHILOHV There are separate template files for each type of kinematic model in the RobotWare: security,
internal and external configuration files. They are further detailed in section )LOHKDQGOLQJ on
page 305

*HQHULF3RVLWLRQ The Generic Position Control (GPC) is a configuration set-up that is used if the cabinet only
&RQWURO controls independent axes. One cabinet can control up to six independent axes.

0RGHOJURXSV The table below describes the different groups of kinematic models.

1RWDWLRQ ,QGLFDWHV
Gantry two to six axes
TopLoader six axes
Doppin Feeder two or three axes

1RWDWLRQLQPRG The kinematic models are designated with a combination of capital letters. The table below
HOV details the meaning of the notations.
The base frame is orientated so that the linear motions are parallell to the directions of the
base frame axes X, Y and Z.

1RWDWLRQ ,QGLFDWHV
X, Y, Z linear motion
A, B, C, D, E, F rotational movement
A(X) rotational movement around X-axis
A(Y) rotational movement around Y-axis
A(Z) rotational movement around Z-axis

)XUWKHULQIRUPD Useful information:

WLRQ • Read about world, base and tool frames in the 8VHU
V*XLGH&RRUGLQDWHV\VWHPV.

224 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.2 Kinematic model X_Y_Z

.LQHPDWLFPRGHO;B<B=

'HVFULSWLRQ The X_Y_Z is a kinematic model, based on an area gantry concept, with three linear motions
and no rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z.

xx0300000614

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion

3HAC 021333-001 A 225

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.3 Kinematic model X_Y_Z_C(Z)

.LQHPDWLFPRGHO;B<B=B&=

'HVFULSWLRQ The X_Y_Z is a kinematic model, based on an area gantry concept, with three linear motions
and one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z_C(Z).

xx0300000616

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion
C C rotating around Z axis in base frame

226 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.4 Kinematic model X_Y_Z_B(X)

.LQHPDWLFPRGHO;B<B=B%;

'HVFULSWLRQ The X_Y_Z_B(X) is a kinematic model, based on an area gantry concept, with three linear
motions and one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z_B(X).

xx0300000617

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion
B B rotating around X axis in base frame
a RIIVHWB] of arm "irc_6"

3HAC 021333-001 A 227

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.5 Kinematic model X_Y_Z_B(Y)

.LQHPDWLFPRGHO;B<B=B%<

'HVFULSWLRQ The X_Y_Z_B(Y) is a kinematic model, based on an area gantry concept, with three linear
motions and one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z_B(Y).

xx0300000618

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion
B B rotating around Y axis in base frame
a RIIVHWB] of arm "irc_6"

228 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.6 Kinematic model X_Y_Z_B(X)_A(Z)

.LQHPDWLFPRGHO;B<B=B%;B$=

'HVFULSWLRQ The X_Y_Z_B(X)_A(Z) is a kinematic model, based on an area gantry concept, with three
linear motions and two rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z_B(X)_A(Z).

xx0300000619

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion
B B rotating around X axis in base frame
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "irc_6"

3HAC 021333-001 A 229

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.7 Kinematic model X_Y_Z_B(Y)_A(Z)

.LQHPDWLFPRGHO;B<B=B%<B$=

'HVFULSWLRQ The X_Y_Z_B(Y)_A(Z) is a kinematic model, based on an area gantry concept, with three
linear motions and two rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for area gantry X_Y_Z_B(Y)_A(Z).

xx0300000620

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linar motion
Z Z-linear motion
B B rotating around Y axis in base frame
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "irc_6"

230 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.8 Kinematic model X_Y_Z_C(Z)_B(X)_A(Z)

.LQHPDWLFPRGHO;B<B=B&=B%;B$=

'HVFULSWLRQ The X_Y_Z_C(Z)_B(X)_A(Z) is a kinematic model, based on an area gantry concept, with
three linear motions and three rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for X_Y_Z_C(Z)_B(X)_A(Z).

xx0300000621

D World frame
E Base frame
F Tool frame
X X-linear motion
Y Y-linear motion
Z Z-linear motion
C C rotating around Z axis in base frame
B B rotating around X axis in base frame when C is zero
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "gty_a"

3HAC 021333-001 A 231

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.9 Kinematic model Y_Z

.LQHPDWLFPRGHO<B=

'HVFULSWLRQ The Y_Z is a kinematic model, based on a linear gantry, with two linear motions and no
rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z.

xx0300000622

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion

232 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.10 Kinematic model Y_Z_C(Z)

.LQHPDWLFPRGHO<B=B&=

'HVFULSWLRQ The Y_Z_C(Z) is a kinematic model, based on a linear gantry, with two linear motions and
one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_C(Z).

xx0300000623

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
C C rotating around Z axis in base frame

3HAC 021333-001 A 233

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.11 Kinematic model Y_Z_B(X)

.LQHPDWLFPRGHO<B=B%;

'HVFULSWLRQ The Y_Z_B(X) is a kinematic model, based on a linear gantry, with two linear motions and
one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_B(X).

xx0300000624

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
B B rotating around X axis in base frame
a RIIVHWB] of arm "irc_6"

234 A 3HAC 021333-001

 ,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.12 Kinematic model Y_Z_B(Y)

.LQHPDWLFPRGHO<B=B%<

'HVFULSWLRQ The Y_Z_B(Y) is a kinematic model, based on a linear gantry, with two linear motions and
one rotation.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_B(Y).

xx0300000625

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
a RIIVHWB] of arm "irc_6"

3HAC 021333-001 A 235

,5&6&SOXV&RQWURORIQRQ$%%PDQLSXODWRU
6.2.13 Kinematic model Y_Z_B(X)_A(Z)

.LQHPDWLFPRGHO<B=B%;B$=

'HVFULSWLRQ The Y_Z_B(X)_A(Z) is a kinematic model, based on a linear gantry, with two linear motions
and two rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_B(X)_A(Z).

xx0300000626

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
B B rotating around X axis in base frame
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "irc_6"

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6.2.14 Kinematic model Y_Z_B(Y)_A(Z)

.LQHPDWLFPRGHO<B=B%<B$=

'HVFULSWLRQ The Y_Z_B(Y)_A(Z) is a kinematic model, based on a linear gantry, with two linear motions
and two rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_B(Y)_A(Z).

xx0300000627

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
B B rotating around Y axis in base frame
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "irc_6"

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6.2.15 Kinematic model Y_Z_C(Z)_B(X)_A(Z)

.LQHPDWLFPRGHO<B=B&=B%;B$=

'HVFULSWLRQ The Y_Z_C(Z)_B(X)_A(Z) is a kinematic model, based on a linear gantry, with two linear
motions and three rotations.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_Z_C(Z)_B(X)_A(Z).

xx0300000628

D World frame
E Base frame
F Tool frame
Y Y-linear motion
Z Z-linear motion
C C rotating around Z axis in base frame
B B rotating around X axis in base frame when C is zero
A A rotating around Z axis in base frame if B is zero
a RIIVHWB] of arm "irc_6"

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6.2.16 Kinematic model Y_E(Y)_D(Y)_C(Y)_B(Y)_A(Z)

.LQHPDWLFPRGHO<B(<B'<B&<B%<B$=

'HVFULSWLRQ The Y_E(Y)_D(Y)_C(Y)_B(Y)_A(Z) is a six axes kinematic model and is based on a Top-
Loader concept. It consists of a manipulator with five rotating axes that can move with a
linear movement. The home position is shown in the figure below.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for Y_E(Y)_D(Y)_C(Y)_B(Y)_A(Z).

xx0300000629

D World frame
E Base frame
F Tool frame
J-1 Joint irc_1 linear along Y axis in base frame
J-2 Joint irc_2 rotating around X axis in base frame
J-3 irc_3 rotating around X axis in base frame
J-4 Joint irc_4 rotating around Z axis in base frame if the others are zero
J-5 Joint irc_5 rotating around X axis in base frame if the others are zero
J-6 Joint irc_6 rotating around Z axis in base frame if the others are zero
a RIIVHWB] of arm "irc_4"
b RIIVHWB] of arm "irc_6"
c OHQJWK of arm "irc_3"
d OHQJWK of arm "irc_2"

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6.2.17 Doppin Feeder

'RSSLQ)HHGHU

'HVFULSWLRQ The Doppin Feeder is a two or three axes kinematical model. (doppin_2: 2 axes, doppin_3: 3
axes)
Home position for this model is with the arm "irc_2" pointing vertically upwards.

,OOXVWUDWLRQ The figure below illustrates the kinematic model for the Doppin Feeder.
1RWH The moving revolute joint irc_2 will result in a non-linear motion of the tool frame if
the length of the arm "irc_2" is not equal to the length of the arm "irc_3". The linear motion
along irc_1 and irc_3 moves the whole mechanism.

xx0300000630

E Base frame
F Tool frame
J-1 Joint irc_1 linear along Y axis in base frame
J-2 Joint irc_2 rotating around Y axis in base frame
J-3 Joint irc_3 linear along Z axis in base frame
a RIIVHWB] of arm "irc_2"
b RIIVHWB[ of arm "irc_2"
c OHQJWK of arm "irc_2"
d OHQJWK of arm "irc_3"

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6.3.1 Introduction

&RQILJXUDWLRQ

,QWURGXFWLRQ

2YHUYLHZ This section is divided into two sub-sections:

• 0LQLPDOFRQILJXUDWLRQ. This sub-section contains a description of all the parameters
that must be set before start-up of the robot system.
• 3DUDPHWHUGHVFULSWLRQ on page 254. This sub-section contains a description of all the
parameters that are available in the controller and possible to set for the configuration
of the robot system.

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6.3.2.1 Introduction

0LQLPDOFRQILJXUDWLRQ

,QWURGXFWLRQ

2YHUYLHZ This section describes parts that are general for the minimal configuration.

'HIDXOWFRQILJXUD For every permissible variant of the cabinet and built-in kinematic model a corresponding set
WLRQILOHVIRUNLQH of default configuration files are supplied with the software. To make the configuration as
PDWLFPRGHOV simple as possible it is important that these files are used as a starting point.
The set of default configuration files consists of the following three template files:
• Security configuration file (s)
• Internal configuration file (i)
• External configuration file (e).
Once the RobotWare is installed in the computer, the default configuration files for the dif-
ferent kinematic models can be found on the PC hard drive, as detailed in section )LOHKDQ
GOLQJ on page 305.

'HWHUPLQHDFWXDO The actual default configuration files that are to be used as a starting point are determined by
FRQILJXUDWLRQILOH the type of kinematic model that is to be used, see .LQHPDWLFPRGHOV on page 224. If, for
example, a gantry with X_Y_Z kinematic model is to be configured, the default configuration
files are named ;B<B=BLFIJand ;B<B=BHFIJ.

'HIDXOWFRQILJXUD The default configuration files are made so that the three first axes have linear motion,
WLRQILOHVIRULQGH whereas the last three axes are rotating.
SHQGHQWD[HV For independant axes, the default configuration files to be modified are found in following
directory:
ABB Robotics\MediaPool\3HAC6811-1.xx\utility\extaxis\sac\

0RGLILFDWLRQRI This chapter describes modification of the default configuration files with use of a text editor.
GHIDXOWFRQILJXUD It is important to note that many of the parameters have different names on the TPU. How-
WLRQILOHV ever, some parameters are suitable for editing from the TPU and this is commented on where
it appears.
If editing is done from the TPU, the data must later be exported and entered into the config-
uration files manually. Otherwise there is a risk that data will be lost. When a back-up is made
only the external configuration file will be saved. The internal configuration file is not
updated automatically with the new values set from the TPU.
1RWHTo be able to read and change some of the parameters from the TPU, the system must
be booted in service mode.

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6.3.2.1 Introduction

)XUWKHULQIRUPD For installing and changing parameter data see 8VHU

V*XLGH, section 6\VWHP3DUDPHWHUV
WLRQ 7RSLF0DQLSXODWRU.

6DIHW\LQIRUPD Observe following safety information.

WLRQ

:DUQLQJ
Incorrect definitions of the system parameters may cause damage to the robot or personal
injury. Make sure that safety instructions are carefully followed.

3HAC 021333-001 A 243

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6.3.2.2 External configuration file

([WHUQDOFRQILJXUDWLRQILOH

&$%/(

3DUDPHWHU 'HVFULSWLRQ
name Name of the cable data group, max 16 characters.
use_cable_type Name of the cable_type data group. This is defined in the security
file and is named after the cable area.
length Length of cable (in meter).

The electrical data for various cables are defined in the security file and named after the
conductor area.

02725B&$/,%

3DUDPHWHU 'HVFULSWLRQ
cal_offset Position of rotor at calibration position. This is an angle between
0-2pi (in radians).

This parameter can be updated from the TPU by moving the axes to their calibration positions
and then fine-calibrated from the Service window. From the TPU, choose
7\SHV?0RWRUBFDOLEUDWLRQand define the calibration and commutation offsets as described in
8VHU
V*XLGHsection 6\VWHP3DUDPHWHUV7RSLF0DQLSXODWRU'HILQLQJWKHFRPPXWDWLRQRII
VHWDQGFDOLEUDWLRQRIIVHWRIWKHPRWRUV.

/,1($5B-2* These parameters determine the appearance of the axes jog guide in the jog window on the
TPU display when jogging in linear mode.

3DUDPHWHU 'HVFULSWLRQ
cart_lin_no_fix_world_1 This parameter determines the text for the up/
down movement of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_lin_no_fix_world_2 This parameter determines the text for the rota-
tional movements of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_lin_no_fix_world_3 This parameter determines the text for the side
movement (left/right) of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_lin_no_fix_base_1,2,3 Compare above but for jogging in the base frame.
cart_lin_no_fix_tool_1,2,3 Compare above but for jogging in the tool frame.
cart_lin_no_fix_wobj_1,2,3 Compare above but for jogging in the wobj frame.

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6.3.2.2 External configuration file

5(25,(17B-2* These parameters determine the appearance of the axes jog guide in the jog window on the
TPU display when jogging in reorientation mode.

3DUDPHWHU 'HVFULSWLRQ
cart_orient_no_fix_world_1 This parameter determines the text for the up/
down movement of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_orient_no_fix_world_2 This parameter determines the text for the rota-
tional movements of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_orient_no_fix_world_3 This parameter determines the text for the side
movement (left/right) of the joystick.
It is an integer with min value -3 and max value 3.
The sign alters the arrow direction. If set to 0, the
jog direction is disabled.
cart_orient_no_fix_base_1,2,3 Compare above but for jogging in the base frame.
cart_orient_no_fix_tool_1,2,3 Compare above but for jogging in the tool frame.
cart_orient_no_fix_wobj_1,2,3 Compare above but for jogging in the wobj frame.

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6.3.2.3 Internal configuration file

,QWHUQDOFRQILJXUDWLRQILOH

0($685(0(17B
&+$11(/
3DUDPHWHU 'HVFULSWLRQ
measurement_node This parameter determines which measurement node is cou-
pled to the the different axes.
It is an integer between 1-6.

$50

3DUDPHWHU 'HVFULSWLRQ
upper_joint_bound Upper joint limit (arm side) with respect to home position, (in
radians or meter).
This parameter can be modified from the TPU. The name on
the TPU is 3RVLWLYHOLPLW.
lower_joint_bound Lower joint limit (arm side) with respect to home position, (in
radians or meter).
This parameter can be modified from the TPU. The name on
the TPU is 1HJDWLYHOLPLW.
upper_joint_bound_max Maximum value (in radians or meter) for
upper_joint_bound (arm side).
lower_joint_bound_min Minimal value (in radians or meter) for
lower_joint_bound (arm side).
cal_position Calibration position (arm side) with regard to home position
given in base frame, (in radians or meter).

$50B7<3( These parameters need only be changed if using any of the kinematic models: gantry with B-
rotation, Toploader or Doppin Feeder.
For parameters to be changed when using the kinematic model *DQWU\ZLWK%URWDWLRQ, see
table below.

)RUDUP 3DUDPHWHUQDPH 'HVFULSWLRQ

LUFB in the default configuration offset_z Length of arm LUFB(in meter), see
file for kinematic models: illustrations in section .LQHPDWLF
• X_Y_Z_B(X) PRGHOV on page 224.
• X_Y_Z_B(X)_A(Z)
• X_Y_Z_C(Z)_B(X)_A(Z)
• Y_Z_B(X)
• Y_Z_B(Y)
• Y_Z_B(X)_A(Z)
• Y_Z_B(Y)_A(Z)
• Y_Z_C(Z)_B(X)_A(Z)

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6.3.2.3 Internal configuration file

For parameters to be changed when using the kinematic model 7RS/RDGHU, see table below.

)RUDUP 3DUDPHWHUQDPH 'HVFULSWLRQ

LUFB length Length (in meter) according to the illustration in
section ,OOXVWUDWLRQ on page 238.
LUFB length Length (in meter) according to the illustration in
section ,OOXVWUDWLRQ on page 238.
LUFB offset_z Length (in meter) according to the illustration in
section ,OOXVWUDWLRQ on page 238.
LUFB offset_z Length (in meter) according to the illustration in
section ,OOXVWUDWLRQ on page 238.

For parameters to be changed when using the kinematic model 'RSSLQ)HHGHU, see table
below.

)RUDUP 3DUDPHWHUQDPH 'HVFULSWLRQ

LUFB length Length (in meter) for the three parameters
offset_x according to illustration in section 'RSSLQ)HHGHU
offset_z on page 240.

LUFB length Length (in meter) according to illustration in sec-

tion 'RSSLQ)HHGHU on page 240.

Denavit-Hartenberg notation according to ,QWURGXFWLRQWR5RERWLFV0HFKDQLFV &RQWUROis

used, see 'RFXPHQWUHIHUHQFHV.

$&&B'$7$

3DUDPHWHU 'HVFULSWLRQ
wc_acc Worst-case axis acceleration (in rad/s 2 or m/s 2 ). This constraint can be
determined by the maximum motor torque, the drive or the mechanical
unit.
If the value specified is too high, the motor will reach the torque limit and
result in bad path performance.
wc_dec Worst-case axis deceleration (in rad/s 2 or m/s 2 . This constraint can be
determined by the maximum motor torque, the drive or the mechanical
unit.
If the value specified is too high, the motor will reach the torque limit and
the axis will overshoot in finepoints.

75$160,66,21

3DUDPHWHU 'HVFULSWLRQ
transm_joint Gear ratio between motor and axis. It must be given with sign, i.e. if a
positive motor rotation gives an arm movement in negative baseframe
direction the gear ratio should be negative.
For a linear axis the gear ratio is specified as motor rotation in radians
per metre linear movement (21.43 denotes that when the motor rotates
21.43 radians, the axis moves 1 m).

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6.3.2.3 Internal configuration file

3DUDPHWHU 'HVFULSWLRQ
rotating_move Is included if the axis is of the rotating type. Default is linear type.
It is not necessary to change this parameter for the built-in robot kine-
matics models.
high_gear The integer value of the numerator of the transmission gear ratio. Only
used for independent axes.
low_gear The integer value of the denominators of the transmission gear ratio.
Only used for independent axes.
Example: A rotating axis with the high gear value 100 and the low gear
value 30 has a transmission gear ratio of 100/30=3.333333.

%5$.( This data controls the emergency brake behaviour. The description below is relevant if the
axis has a brake, and this brake is strong enough to hold against gravitation.
See the illustration below, which is a simplified description of the emergency brake algo-
rithm.

Start brake

No
Speed > control_off_speed_limit

Normal control during time Yes

FRQWUROBRIIBGHOD\BWLPH
then T=0. Normal control during time
(this prevents axis to drop before EUDNHBFRQWUROBRQBGHOD\BWLPH
activation of mech. brake) (ramp retardation by motor)

No

Normal control during time

Yes
EUDNHBFRQWUROBRQBPLQBGHOD\BWLPH
then T=0. Simulated Electrical Brake
(this prevents axis to drop before (motor torque added to
activation of mech. brake) mech. brake)
xx0400000646

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6.3.2.3 Internal configuration file

3DUDPHWHU 'HVFULSWLRQ
control_off_speed_limit Speed (ratio of max. speed). Used to decide if
control_off_delay_time or
brake_control_on_delay_time is to be
used. If actual speed is less than
control_off_speed_limit , the simulated
electrical brake is not activated. See the illustra-
tion above.
This parameter is also used as a limit for the
simulated electrical brake, see the illustration
below this table.
control_off_delay_time Time (in seconds) for controller to be active until
brake starts to work if speed is less than
control_off_speed_limit (close to zero
speed) at brake activation. During the time
control_off_delay_time , the motor is
controlled as in normal operation. After the time
has expired, the torque is set to zero.
This parameter is typically set to about 150% of
brake activation time. This prevents the axis
dropping before the mechanical brake is active.
brake_control_on_delay_time Time (in seconds) for controller to be active until
brake starts to work if speed is greater than
control_off_speed_limit (significant
speed) at brake activation. During this time the
controller starts a ramp retardation. After the
time has expired, the simulated electrical brake
is activated.
This time should be set close to the activation
time of the mechanical brake. Typical value is
0.060 ms.
brake_control_on_min_delay_time Used if axis has zero speed before
brake_control_on _delay_time has
expired.
Set to same value as
control_off_delay_time .
absolute_brake_torque Brake torque [Nm] for simulated electrical
brake, see the illustration below.
brake_ramp_speed_limit Speed (ratio of max. speed). Point of torque
reduction for simulated electrical brake, see the
illustration below.
This parameter is typically set to zero.
use_brake_type ID name of the brake_type data group (max. 16
characters).

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6.3.2.3 Internal configuration file

Illustrations The illustrations below are schematic sketchs of the mechanical brake and the simulated elec-
trical brake.

xx0400000647

- Schematic sketch of the mechanical brake.

xx0400000650

- The simulated electrical brake is designed to compensate (add brake

torque) for the variation of brake torque of the mechanical brake.

'5,9(B6<67(0

3DUDPHWHU 'HVFULSWLRQ
use_drive_unit Given as unit L_node N, where Lis the unit number (min. 1 and max.
3) and N is the node number (min. 1 and max. 3).
use_cable Name of cable as defined under &$%/(in the external configuration
file, see &$%/( on page 244.

02725

3DUDPHWHU 'HVFULSWLRQ
use_motor_type Name of motor as defined under 02725B7<3( in the internal con-
figuration file. See section below.

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6.3.2.3 Internal configuration file

02725B7<3( The parameters below are necessary and can be found in the motor specifications. If correct
values for the additional parameters in this data group are not available, they should be
removed from the configuration file.

3DUDPHWHU 'HVFULSWLRQ
pole_pairs Number of pole pairs.
Minimum=1 and maximum=6.
torque_0 Stall torque, infinite time, temp_stator_rise to temp_stator_max.
(Newton meter)
ke Nominal voltage constant, induced voltage phase to phase (in Vs/rad).
(1 V/1000 rpm is equivalent to 0.00955 V per rad/s)
i_max Maximum current without irreversible magnetization (RMS).
(Ampere)
r_stator_20 Stator phase resistance at 20 degrees Celsius.
(ohm)
l_stator Stator phase inductance at zero current.
(Henry)

7+(50$/B'87< This data group is important if the motor temperature is limiting the work cycle.
B&<&/(

675(66B'87<B
&<&/(
3DUDPHWHU 'HVFULSWLRQ
speed_absolute_max The absolute highest motor speed to be used (in rad/s).
The maximum value of this parameter is the maximum motor
speed.
torque_absolute_max The absolute highest motor torque to be used (in Newton
meter).
The maximum value of this parameter is the maximum available
motor torque.
If torque_absolute_max is too high it may result in a config-
uration error at restart. This can happen if a more complete
motor definition than described above is used and
torque_absolute_max is much too large. To avoid this, do
not set torque_absolute_max larger than:
torque_absolute_max < sqrt(3)*NH* i_max
where NHis the voltage constant of the motor and i_max is the
maximum current of the used drive module and motor type.

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6.3.2.3 Internal configuration file

8&&0 This data group provides parameters for the uncalibrated control master 0.
These parameters must be tuned according to the section 7XQLQJRID[HVFRPSOHWHSURFHGXUH
on page 286

3DUDPHWHU 'HVFULSWLRQ
Kp Proportional gain in position loop (in loops per second).
This is the amplification of the position control, for example the value 15. A
high value will give a stiff axis that quickly assumes its new position. The
value should be large without inducing overshoot in the position or oscilla-
tions of the axis.
Kv Proportional gain in speed loop (in Nms/rad).
This is the amplification of the velocity control, for example the value 2. A
high value gives better high-frequency stiffness, better response speed
and low overshoot. If the value is too high the axis will vibrate.
Kv controls the amount of damping for the axis and is the most limiting of
the parameters. A poor value of Kv will limit Kp and Ti , and the axis will
not be fully utilised.
Ti Integration time in speed loop (in seconds).
This is the integration interval constant of the velocity control, for example
the value 2. A low value gives low steady state error and better path follow-
ing. If Ti is too small the axis will overshoot and the response will be
oscillatory.
speed_max_n Maximum speed in rad/s (motor side).
acc_max_n Maximum acceleration in rad/s 2 (motor side).
dec_max_n Maximum deceleration in rad/s 2 (motor side).

/&0 This data group provides parameters for the lag control master 0.
These parameters must be tuned according to the section 7XQLQJRID[HVFRPSOHWHSURFHGXUH.

3DUDPHWHU 'HVFULSWLRQ
Kp Proportional gain in position loop (in loops per second).
This is the amplification of the position control, for example the value 15. A
high value will give a stiff axis that quickly assumes its new position. The
value should be large without inducing overshoot in the position or oscilla-
tions of the axis.
Kv Proportional gain in speed loop (in Nms/rad).
This is the amplification of the velocity control, for example the value 2. A
high value gives better high-frequency stiffness, better response speed
and low overshoot. If the value is too high the axis will vibrate.
Kv controls the amount of damping for the axis and is the most limiting of
the parameters. A poor value of Kv will limit Kp and Ti , and the axis will
not be fully utilised.
Ti Integration time in speed loop (in seconds).
This is the integration interval constant of the velocity control, for example
the value 0.2. A low value gives low steady state error and better path
following?? If the value of Ti is too small, the axis will overshoot and the
response will be oscillatory.

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6.3.2.3 Internal configuration file

3DUDPHWHU 'HVFULSWLRQ
ffw_mode Regulator type: no ffw, speed ffw or torque ffw.
0=No
1=Speed
2=Torque

-2,17B-2* These parameters determine the appearance of the axes jog guide in the jog window on the
TPU display when jogging in joint mode.

3DUDPHWHU 'HVFULSWLRQ
joint_1 This parameter determines the text for the up/down movement of the joy-
stick for group 1.
It is an integer with min. value -3 and max. value 3. The sign alters the
arrow direction. If set to 0, the jog direction is disabled.
joint_2 This parameter determines the text for the up/down movement of the joy-
stick for group 1.
It is an integer with min. value -3 and max. value 3. The sign alters the
arrow direction. If set to 0, the jog direction is disabled.
joint_3 This parameter determines the text for the up/down movement of the joy-
stick for group 1.
It is an integer with min. value -3 and max. value 3. The sign alters the
arrow direction. If set to 0, the jog direction is disabled.
joint_4 Same as joint_1 but for group 2.
joint_5 Same as joint_2 but for group 2.
joint_6 Same as joint_3 but for group 2.

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6.3.3.1 Description of ingoing parameters

3DUDPHWHUGHVFULSWLRQ

'HVFULSWLRQRILQJRLQJSDUDPHWHUV

2YHUYLHZ In order to simplify the installation of robots a number of configuration files are delivered
with the system. The configuration files are designed to provide optimum system behaviour
and performance of the robot. A minimal configuration procedure is described in the section
,QWURGXFWLRQ on page 242.
A brief description of the parameters that are relevant to configure, using the controller in
order to control a non-ABB manipulator, are given in this section. Each parameter belongs to
a data group.

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6.3.3.2 MOTION_SYSTEM

027,21B6<67(0

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ MOTION_SYSTEM.

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name System name, max. 16 charac-
ters.
brake_on_timeout Brake on time Brake activation time in motor on
state (in seconds).
Min.=0.3, Max.=3600000,
Default=3600000.
dynamic_resolution Dynamic resolution Dynamic sample time/0.024192.
Min.=0.1667, Max.=1.0,
Default=1.0.
path_resolution Path resolution Geometric sample time/
0.024192.
Min.=0.1667, Max.=6.0,
Default=1.0.
std_servo_queue_time Queue time Standard servo queue time.
Min.=0.004032, Max.=0.290304,
Default=0.096768.
min_temp_ambient_cabinet Min temp cabinet Minimum ambient temperature
for the cabinet.
Min.=-100, Max.=100.
max_temp_ambient_cabinet Max temp cabinet Maximum ambient temperature
for the cabinet.
Min.=-100, Max.=100.
min_temp_ambient_robot Min temp robot Minimum ambient temperature
for the robot.
Min.=-100, Max.=100.
max_temp_ambient_robot Max temp robot Maximum ambient temperature
for the robot.
Min.=-100, Max.=100.
perpendicular_acc_ratio - Perpendicular acceleration ratio.
Min.=0.1, Max.=1.5.
dyn_ipol_decbuf_type - OPTIMAL_TIME - original,
OPTIMAL_PATH - less high
torques.
Max. 24 characters.
micro_ipol_type - micro ipol type 0,..., n.
Min.=0.
cpu_load_added_to_dsp - Used to verify CPU load margin in
DSP.
Min=0, Max=25, Default=0.
motion_sup_max_level Motion sup max level Maximum motion sup level and
tune value.
Min.=10, Max.=500, Default=300.

3HAC 021333-001 A 255

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6.3.3.3 MECHANICAL_UNIT

0(&+$1,&$/B81,7

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ SUPERVISION_TYPE.

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Mechanical unit name.
Max. 16 characters.
use_run_enable Use run enable ID name for run enable input sig-
nal.
Max. 16 characters.
use_activation_relay Use act relay ID name for activation relay.
Max. 16 characters.
use_brake_relay Use brake relay ID name for brake relay.
Max. 16 characters.
use_robot Use robot Mechanical unit contains robot.
Max. 16 characters.
stand_by_state Stand by state If YES, the unit is not controlled
and the brakes are not released
until the first movement instruc-
tion is executed or until it is
moved manually. If NO, then the
unit goes to control on immedi-
ately with Motor on. Must not be
deactivated in the S4C Plus sys-
tem.
activate_at_start_up Activate at start up Activate the mechanical unit at
start-up.
do_not_allow_deactivation Do not allow deact. Mechanical unit is not allowed to
be deactivated.

256 A 3HAC 021333-001

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6.3.3.4 RELAY

5(/$<

3DUDPHWHU The following table contains the parameters that belong to the data group RELAY.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the relay, for example irb_brake (max.
16 characters). This must be changed when
more relays are to be used.
out_signal Output signal Denotes the logical name of the output signal to
the relay. The name must be identical (including
upper and lower case letters) to the name used
for the signal definition.
in_signal Input signal Denotes the logical name of the input signal to
the relay. The name must be identical (including
upper and lower case letters) to the name used
for the signal definition.

3HAC 021333-001 A 257

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6.3.3.5 ROBOT

52%27

3DUDPHWHU The following table contains the parameters that belong to the data group ROBOT.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the robot, for example
master.
Max. 16 characters.
use_robot_type Use robot type Name of kinematic model accord-
ing to gantry-type kinematic mod-
els, see section .LQHPDWLFPRGHOV
on page 224.
use_joint_0 Use joint 1 ID name of 1st axis, for example
irc_1.
Max. 16 characters.
use_joint_1 Use joint 2 ID name of 2nd axis, for example
ire_2.
Max. 16 characters.
use_joint_2 Use joint 3 ID name of 3rd axis, for example
irc_3.
Max. 16 characters.
use_joint_3 Use joint 4 ID name of 4th axis, for example
irc_4.
Max. 16 characters.
use_joint_4 Use joint 5 ID name of 5th axis, for example
irc_5.
Max. 16 characters.
use_joint_5 Use joint 6 ID name of 6th axis, for example
irc_6.
Max. 16 characters.
base_frame_pos_x Base frame x Base frame position in respect of
world frame coordinate system, x-
direction (in meters).
Min.=-1000, Max.=1000,
Default=0.
base_frame_pos_y Base frame y Base frame position in respect of
world frame coordinate system, y-
direction (in meters).
base_frame_pos_z Base frame z Base frame position in respect of
world frame coordinate system, z-
direction (in meters).
base_frame_orient_u0 Base frame q1 Base frame orientation in respect of
world frame coordinate system,
first quaternion (q1).
Min.=-1, Max.=1, Default=0.
base_frame_orient_u1 Base frame q2 Base frame orientation in respect of
world frame coordinate system,
second quaternion (q2).

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6.3.3.5 ROBOT

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

base_frame_orient_u2 Base frame q3 Base frame orientation in respect of
world frame coordinate system,
third quaternion (q3).
base_frame_orient_u3 Base frame q4 Base frame orientation in respect of
world frame coordinate system,
fourth quaternion (q4).
rot_x_tol Orient tol about x Orientation tolerance (in radians).
Min.=0, Max.=4, Default=0.001.
rot_y_tol Orient tol about y Orientation tolerance (in radians).
rot_z_tol Orient tol about z Orientation tolerance (in radians).

Here follows an example of how to set the parameters in the configuration files when using
the kinematic model described in the section .LQHPDWLFPRGHO;B<B=B%;B$= on page
229. The configuration files to be edited are *_e.cfg and *_i.cfg (the asterisk is a designation
of the file ID for a specific kinematic model), for file handling see the section )LOHKDQGOLQJ
on page 305.
Example:
-name "master"
-use_robot_type "IRC_X_Y_Z_BX_AZ"
-use_joint_0 "irc_1"
-use_joint_1 "irc_2"
-use_joint_2 "irc_3"
-use_joint_3 "irc_4"
-use_joint_4 "irc_5"
-use_joint_5 "irc_6"
-rot_x_tol 0.0005, -rot_y_tol 0.0005, -rot_z_tol 0.0005

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6.3.3.6 MEASUREMENT_CHANNEL

0($685(0(17B&+$11(/

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ MEASUREMENT_CHANNEL.

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the
MEASUREMENT_CHAN
NEL data group, e.g. x.
Max. 16 characters.
use_measurement_board_type Use mea. board type Measurement board type.
Max. 16 characters.
measurement_system Measurement system The number of the mea-
surement system.
The number is 1 or 2.
Default=1.
board_position Board position The number of the board.
The number is 1 or 2.
Default=1.
measurement_node Measurement node Measurement node.
Node number: 1 to 7.
Default=1.

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6.3.3.7 ARM

$50

*HQHUDO This data group provides parameters that are applicable to each arm of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group ARM.
GHVFULSWLRQ

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Name of the ARM data group, e.g. x.
Max. 16 characters.
use_arm_type Use arm type ID name for ARM_TYPE data group.
Max. 16 characters.
use_acc_data Use acc data ID name for ACC_DATA data group.
Max. 16 characters.
use_arm_calib Use arm calib ID name for ARM_CALIB data group.
Max. 16 characters.
upper_joint_bound Upper joint bound Upper joint limit (arm side).
(Radians or meters.)
lower_joint_bound Lower joint bound Lower joint limit (arm side).
(Radians or meters.)
upper_joint_bound_max - Maximum value for
upper_joint_bound (arm side).
(Radians or meters.)
lower_joint_bound_min - Minimal value for lower_joint_bound
(arm side).
(Radians or meters.)
cal_position Calibration position Calibration position (arm side).
(Radians or metres.)

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6.3.3.8 ARM_TYPE

$50B7<3(

*HQHUDO This data group provides parameters that are applicable to each arm of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group ARM_TYPE.
GHVFULSWLRQ

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
name Name Name of the ARM_TYPE data group.
Max. 16 characters.
length - Arm length (a according to Craig’s definition,
see reference below).
(Meter)
offset_x - Offset between 1st and 2nd axes of the arm,
x direction.
(Meter)
offset_y - Offset between 1st and 2nd axes of the arm,
y direction.
(Meter)
offset_z - Offset between 1st and 2nd axes of the arm,
z direction.
(Meter)
theta_home_position - Axis angle of arm in home position (theta
according to Craig’s definition).
(Radians)
attitude - Angle between the two axes of the arm (alpha
according to Craig’s definition).
(Radians)

The Denavit-Hartenberg notation according to John J. Craig in ,QWURGXFWLRQWR5RERWLFV

0HFKDQLFVDQG&RQWUROis used, see 'RFXPHQWUHIHUHQFHV.

262 A 3HAC 021333-001

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6.3.3.9 ACC_DATA

$&&B'$7$

*HQHUDO This data group provides parameters that are applicable to each arm of the external robot in
question.

3DUDPHWHU The following table contains the parameters that belong to the data group ACC_DATA.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the ACC_DATA data group.
Max. 16 characters.
wc_acc Nominal acceleration Worst case motor acceleration (arm side).
(rad/s 2 )
wc_dec Nominal deceleration Worst case motor deceleration (arm side).
(rad/s 2 )

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6.3.3.10 ARM_CALIB

$50B&$/,%

*HQHUDO This data group provides parameters that are applicable to each arm of the external robot in
question.

3DUDPHWHU The following table contains the parameters that belong to the data group ARM_CALIB.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the ARM_CALIB data group.
Max. 16 characters.

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6.3.3.11 TRANSMISSION

75$160,66,21

*HQHUDO This data group provides parameters that are applicable to each arm of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group TRANSMISSION.
GHVFULSWLRQ

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Name of the TRANSMISSION data group.
Max. 16 characters.
transm_joint Transm gear ratio Gear ratio between motor and axis. For a linear
axis the gear ratio is specified as motor rotation in
radians per metre linear movement (21.43
denotes that when the motor rotates 21.43 radi-
ans, the axis moves 1 meter).
rotating_move Rotating move Is included if the axis is of the rotating type.
Default is linear type.
high_gear Transm gear high The integer value of the numerator of the trans-
mission gear ratio. Only used for independent
axes.
low_gear Transm gear low The integer value of the denominators of the
transmission gear ratio. Only used for indepen-
dent axes.
Example: A rotating axis with high gear 100 and
low gear 30 has a transmission gear ratio of 100/
30=3.333333.

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6.3.3.12 BRAKE

%5$.(

*HQHUDO This data controls the emergency brake behaviour. The description below is relevant if the
axis has a brake, and this is strong enough to hold against gravitation.

3DUDPHWHU The following table contains the parameters that belong to the data group BRAKE.
GHVFULSWLRQ

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
name Name Name of the BRAKE data group.
Max. 16 characters.
control_off_speed_limit Ctrl off spd lim Speed (ratio of max. speed). This
parameter is used to decide if
control_off_delay_time or
brake_control_on_delay_time
is to be used. If actual speed is less
than control_off_speed_limit
, the simulated electrical brake is not
activated, see the flowchart in the
section %5$.( on page 248.
This parameter is also used as a limit
for the simulated electrical brake, see
the illustrations in the subsection
,OOXVWUDWLRQV on page 250 .
control_off_delay_time Control off Time (in seconds) for controller to be
delay active until brake starts to work if
speed is less than
control_off_speed_limit
(close to zero speed) at brake activa-
tion. During the time
control_off_delay_time, the
motor is controlled as in normal oper-
ation. After the time has expired, the
torque is set to zero.
This parameter is typically set to
about 150% of brake activation time.
This prevents the axis dropping
before the mechanical brake is
active.
brake_control_on_delay_time Brake ctrl on Time (in seconds) for controller to be
delay active until brake starts to work if
speed is less than
control_off_speed_limit
(significant speed) at brake activa-
tion. During this time the controller
starts a retardation. After the time
has expired, the simulated electrical
brake is activated.
This time should be set close to the
activation time of the mechanical
brake. Typical value is 0.060 ms.

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6.3.3.12 BRAKE

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
brake_control_on_min_delay_ Brake ctrl min Set to same value as
time delay control_off_delay_time.
absolute_brake_torque Abs. brake Brake torque (in Nm) for simulated
torque electrical brake, see the illustrations
in the subsection ,OOXVWUDWLRQV on
page 250. This should compensate
for the variation in mechanical brake
torque with speed.
brake_ramp_speed_limit Brake ramp Speed (ratio of max. speed). Point of
spd lim torque reduction for simulated electri-
cal brake see the illustrations in the
subsection ,OOXVWUDWLRQV on page 250.
This parameter is typically set to
zero.
use_brake_type Use brake ID name of the BRAKE_TYPE data
type group.
Max. 16 characters.

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6.3.3.13 BRAKE_TYPE

%5$.(B7<3(

3DUDPHWHU The following table contains the parameters that belong to the data group BRAKE_TYPE.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the BRAKE_TYPE data group.
Max. 16 characters.
inertia Inertia Inertia of the brake (in kgm 2 ).

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6.3.3.14 SUPERVISION

683(59,6,21

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group SUPERVISION.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the SUPERVI-
SION data group.
Max. 16 characters.
use_supervision_type Use supervision type ID name of
SUPERVISION_TYPE
data group.
Max. 16 characters.
power_up_position_on power_up_position_on Power up position supervi-
sion on, default is off.
counter_supervision_on Counter supervision Counter supervision on,
default is off.
position_supervision_on Pos supervision Position supervision on,
default is off.
speed_supervision_on Speed supervision Speed supervision on,
default is off.
load_supervision_on Load supervision Load supervision on,
default is off.
jam_supervision_on Jam supervision Jam supervision on,
default is off.
in_position_range In position range -
normalized_zero_speed Zero speed ( % ) -
dsp_torque_limitation_zero_ - Deadband speed width (in
speed_width rad/s on motor side).

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6.3.3.15 SUPERVISION_TYPE

683(59,6,21B7<3(

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ SUPERVISION_TYPE.

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
name Name Name of the
SUPERVISION_TYPE data
group.
Max. 16 characters.
static_power_up_position_limit - Static power up position error
limit at zero speed (in radi-
ans).
Min.=0, Max.=30.
dynamic_power_up_position_limit Dyn pwr up pos Dynamic power up position
lim error limit at zero speed (in
radians).
static_position_limit - Position error limit at zero
speed (in radians).
dynamic_position_limit - Position error limit at zero
speed (in radians).
static_normalized_speed_limit - Speed error limit at zero
speed (% max. speed).
dynamic_normalized_speed_limit - Speed error limit at max
speed (% max. speed).
normalized_influence_sensitivity - Speed error influence sensi-
tivity reduction (% max.
speed).
speed_half_time - Declination factor half time
for supervision limits (in sec-
onds).
Min.=0, Max.=5.
max_jam_normalized_speed - Speed limit for jam versus
over load supervision (%
max. speed).
max_overload_time Max overload Maximum overload time (in
time seconds).
Min.=0, Max.=20.
max_jam_time Max jam time Max jam time (in seconds).
Min.=0, Max.=20.
teach_mode_speed_max_main Teach max spd Maximum speed in teach
main mode for IPOL task, (% max
speed).
Min.=0, Max.=1,
Default=0.15.

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6.3.3.15 SUPERVISION_TYPE

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
teach_normalized_low_speed Teach norm low Servo supervision limit (%
spd max speed).
Min.=0, Max.=1,
Default=0.25.
teach_mode_speed_max_dsp Teach max spd Maximum speed in teach
dsp mode for dsp computer, (%
max speed).
Min.=0, Max.=1,
Default=0.28.

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6.3.3.16 DRIVE_SYSTEM

'5,9(B6<67(0

3DUDPHWHU The following table contains the parameters that belong to the data group DRIVE_SYSTEM.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

use_drive_unit Use drive unit Given as unit L_node N, where Lis the unit
number (min. 1 and max. 3) and N is the
node number (min. 1 and max. 3).
use_cable Use cable Name of cable as defined under &$%/(,
see &$%/( on page 273.

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6.3.3.17 CABLE

&$%/(

3DUDPHWHU The following table contains the parameters that belong to the data group CABLE.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the CABLE data group.
Max. 16 characters.
use_cable_type CABLE_TYPE Name of the cable_type data group. This is
defined in the security file and is named
after the cable area.
Max. 16 characters.
length Length Cable length (in metres).
Min.=0, Max.=200.

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6.3.3.18 MOTOR

02725

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group MOTOR.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the MOTOR data group.
Max. 16 characters.
use_motor_type MOTOR_TYPE ID name of MOTOR_TYPE data
group.
Max. 16 characters.
use_motor_calib Use motor calibration ID name of MOTOR_CALIB data
group.
Max. 16 characters.
stator_cooling_factor - Cooling factor for the stator, multi-
plied with attribute torque_0.
Min.=0, Max.=10, Default=1.

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6.3.3.19 MOTOR_TYPE

02725B7<3(

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group MOTOR_TYPE.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the MOTOR_TYPE
data group.
Max. 16 characters.
pole_pairs Pole pairs Number of pole pairs.
Min.=0, Max.=6.
inertia - Motor and resolver inertia on
motor side (in kgm 2 ).
torque_0 Cont stall torq.(Nm) Stall torque, infinite time,
temp_stator_rise to
temp_stator_max .
(Newton meter)
ke ke phase-ph.(Vs/rad) Nominal voltage constant,
induced voltage phase to
phase (in V/rad/s).
(1 V/1000 rpm is equivalent to
0.00955 V/rad/s)
ke_temp_coef_20 - Temperature reduction coeffi-
cient for ke, at 20º.
(1/K)
ke_stability_coef_20 - Long-term stability reduction
constant for ke after 40000
hours.
ke_tolerance_min - Minimum tolerance for ke (%/
100).
Min. ke =
ke*(1+ke_tolerance_min).
ke_tolerance_max - Maximum tolerance for ke (%/
100).
Max. ke =
ke*(1+ke_tolerance_max).
ke_red_2i0 - Current dependent reduction of
ke at two times rated current
(%/100).
i_max Max Current (A rms) Maximum current without irre-
versible magnetization, (RMS).
(Ampere)
torque_losses_at_speed1 - Total torque losses due to fric-
tion and iron losses at speed1
(cf. below).
(Newton meter)

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6.3.3.19 MOTOR_TYPE

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

torque_losses_at_speed2 - Total torque losses due to fric-
tion and iron losses at speed2
(cf. below).
(Newton meter)
torque_losses_at_speed3 - Total torque losses due to fric-
tion and iron losses at speed3
(cf. below).
(Newton meter)
speed1 - The speed at which
torque_losses_at_speed
1 is defined (in rad/s).
speed2 - The speed at which
torque_losses_at_speed
2 is defined (in rad/s).
speed3 - The speed at which
torque_losses_at_speed
3 is defined (in rad/s).
temp_stator_max - Maximum temperature for the
stator winding (in degrees Cel-
sius).
temp_stator_rise - Maximum temperature rise for
the stator winding (in degrees
Celsius).
temp_rotor_max - Maximum temperature for the
rotor (in degrees Celsius).
temp_rotor_rise - Maximum allowed temperature
rise for the rotor (in degrees
Celsius).
r_stator_20 Phase resistance(ohm) Stator phase resistance at 20
degrees Celsius.
(ohm)
r_stator_temp_coef_20 - Temperature coefficient for the
stator resistance at 20 degrees
Celsius.
(1/K)
l_stator Phase inductance (H) Stator phase inductance at
zero current.
(Henry)

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6.3.3.20 MOTOR_ CALIB

02725B&$/,%

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group MOTOR_CALIB.
GHVFULSWLRQ

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Name of the MOTOR_CALIB data group.
(Max. 16 characters.)
com_offset Commutator offset Normally, commutation does not need to be
implemented because the motors supplied by
ABB are precommutated with the commuta-
tion value 1.5708.
For an uncommutated motor follow these
steps for input commutation offset:
1. Ensure that the motor is not affected by
large external torques (gravity and fric-
tion).
2. Connect a DC power supply to the
motor (S-phase +, T-phase -, R-phase
not connected).
3. Feed the motor with as large a current
as possible, taking note of the max.
permissible currents of the motor.
4. Release the motor brake.
5. The motor will now move to the com-
mutation position.
6. Commutate the motor from the Service
window.
valid_com_offset Com offset valid TRUE if com_offset is valid.
cal_offset Calibration offset Calibration offset (motor side). Can be
updated by moving the axes to their calibration
positions and then fine-calibrating from the
Service window.
(Radians)
valid_cal_offset Cal offset valid TRUE if cal_offset is valid.

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6.3.3.21 THERMAL_DUTY_CYCLE

7+(50$/B'87<B&<&/(

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ THERMAL_DUTY_CYCLE.

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the THERMAL_DUTY_CYCLE data
group.
(Max. 16 characters.)

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6.3.3.22 STRESS_DUTY_CYCLE

675(66B'87<B&<&/(

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group
GHVFULSWLRQ STRESS_DUTY_CYCLE.

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Name of the STRESS_DUTY_CYCLE
data group.
(Max. 16 characters.)
speed_absolute_max Speed abs. max The absolute highest motor speed to be
used.
(rad/sec)
torque_absolute_max Torque abs. max The absolute highest motor torque to be
used (in rad/sec).
If torque_absolute_max is too high it
may result in a configuration error at
restart. This can happen if a more complete
motor definition than described above is
used and torque_absolute_max is
much too large. To avoid this, do not set
torque_absolute_max larger than:
torque_absolute_max < sqrt(3)*NH*
i_max
where NHis the voltage constant of the
motor and i_max is the maximum current
of the used drive module and motor type.

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6.3.3.23 UCCM0

8&&0

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group UCCM0.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the UCCM0 data group.
(Max. 16 characters.)
Kp Kp, gain pos loop Proportional gain in position loop (in loops per
second). A high value will give a stiff axis that
quickly assumes its new position. The value
should be large without inducing overshoot in
the position or oscillations of the axis.
Kv Kv, gain speed loop Proportional gain in speed loop (in Nms/rad). A
high value gives better high-frequency stiffness,
better response speed and low overshoot. If the
value is too high the axis will vibrate.
Kv controls the amount of damping for the axis
and is the most limiting of the parameters. A
poor value of Kv will limit Kp and Ti , and the
axis will not be fully utilised.
Ti Ti i-time speed loop Integration time in speed loop (in seconds). A
low value gives low steady state error and bet-
ter path following. If Ti is too small the axis will
overshoot and the response will be oscillatory.
speed_max_n Speed max uncal Maximum speed (motor side).
(rad/s)
acc_max_n Acc max uncal Max acceleration (motor side).
(rad/s 2 )
dec_max_n Dec max uncal Maximum deceleration (motor side).
(rad/s 2 )

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6.3.3.24 LCM0

/&0

*HQHUDO This data group provides parameters that are applicable to each axis of the robot in question.

3DUDPHWHU The following table contains the parameters that belong to the data group LCM0.
GHVFULSWLRQ

'HVLJQDWLRQRQ
3DUDPHWHU 'HVFULSWLRQ
738
name Name Name of the LCM0 data group.
(Max. 16 characters.)
Kp Kp, gain pos loop Proportional gain in position loop (in
loops per second). A high value will give
a stiff axis that quickly assumes its new
position. The value should be large with-
out inducing overshoot in the position or
oscillations of the axis.
Kv Kv, gain speed loop Proportional gain in speed loop (in Nms/
rad). A high value gives better high-fre-
quency stiffness, better response speed
and low overshoot. If the value is too
high the axis will vibrate.
Kv controls the amount of damping for
the axis and is the most limiting of the
parameters. A poor value of Kv will limit
Kp and Ti , and the axis will not be fully
utilised.
Ti Ti i-time speed loop Integration time in speed loop (in sec-
onds). A low value gives low steady state
error and better path following. If Ti is
too small the axis will overshoot and the
response will be oscillatory.
ffw_mode Feedforward mode Regulator type: no ffw, speed ffw or
torque ffw.
0=No, 1=Speed, 2=Torque.
bandwidth Bandwidth Bandwidth of position reference (used in
lp filter).
resonance_frequency Df Resonance frequency (flexibility com-
pensation filter). Dynamic factor that can
be used to damp oscillations of the axis
due to mechanical resonance.
inertia Inertia External axis inertia in kgm 2 (if rotation)
or mass in kg (if translation).

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6.3.3.25 LINEAR_JOG

/,1($5B-2*

3DUDPHWHU The following table contains the parameters that belong to the data group LINEAR_JOG.
GHVFULSWLRQ

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
name Name Name of the LINEAR_JOG data group.
(Max. 16 characters.)
cart_lin_no_fix_world_1 World down This parameter determines the text for
the up/down movements of the joystick.
It is an integer with min. value -3 and
max. value 3. The sign alters the arrow
direction. If set to 0, the jog direction is
disabled.
cart_lin_no_fix_world_2 World rot This parameter determines the text for
the rotational movements of the joystick.
It is an integer with min. value -3 and
max. value 3. The sign alters the arrow
direction. If set to 0, the jog direction is
disabled.
cart_lin_no_fix_world_3 World side This parameter determines the text for
the side (left/right) movement of the joy-
stick. It is an integer with min. value -3
and max. value 3. The sign alters the
arrow direction. If set to 0, the jog direc-
tion is disabled.
cart_lin_no_fix_base_1 Base down Compare above but for jogging in the
base frame.
cart_lin_no_fix_base_2 Base rot Compare above but for jogging in the
base frame.
cart_lin_no_fix_base_3 Base side Compare above but for jogging in the
base frame.
cart_lin_no_fix_tool_1 Tool down Compare above but for jogging in the
tool frame.
cart_lin_no_fix_tool_2 Tool rot Compare above but for jogging in the
tool frame.
cart_lin_no_fix_tool_3 Tool side Compare above but for jogging in the
tool frame.
cart_lin_no_fix_wobj_1 Wobj down Compare above but for jogging in the
wobj frame.
cart_lin_no_fix_wobj_2 Wobj rot Compare above but for jogging in the
wobj frame.
cart_lin_no_fix_wobj_3 Wobj side Compare above but for jogging in the
wobj frame.

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6.3.3.26 REORIENT_JOG

5(25,(17B-2*

3DUDPHWHU The following table contains the parameters that belong to the data group REORIENT_JOG.
GHVFULSWLRQ

'HVLJQDWLRQ
3DUDPHWHU 'HVFULSWLRQ
RQ738
name Name Name of the REORIENT_JOG data
group.
(Max. 16 characters.)
cart_orient_no_fix_world_1 World down This parameter determines the text
for the up/down movement of the
joystick. It is an integer with min.
value -3 and max. value 3. The sign
alters the arrow direction. If set to 0,
the jog direction is disabled.
cart_orient_no_fix_world_2 World rot This parameter determines the text
for the rotational movements of the
joystick. It is an integer with min.
value -3 and max. value 3. The sign
alters the arrow direction. If set to 0,
the jog direction is disabled.
cart_orient_no_fix_world_3 World side This parameter determines the text
for the side (left/right) movement of
the joystick. It is an integer with min.
value -3 and max. value 3. The sign
alters the arrow direction. If set to 0,
the jog direction is disabled.
cart_orient_no_fix_base_1 Base down Compare above but for jogging in the
base frame.
cart_orient_no_fix_base_2 Base rot Compare above but for jogging in the
base frame.
cart_orient_no_fix_base_3 Base side Compare above but for jogging in the
base frame.
cart_orient_no_fix_tool_1 Tool down Compare above but for jogging in the
tool frame.
cart_orient_no_fix_tool_2 Tool rot Compare above but for jogging in the
tool frame.
cart_orient_no_fix_tool_3 Tool side Compare above but for jogging in the
tool frame.
cart_orient_no_fix_wobj_1 Wobj down Compare above but for jogging in the
wobj frame.
cart_orient_no_fix_wobj_2 Wobj rot Compare above but for jogging in the
wobj frame.
cart_orient_no_fix_wobj_3 Wobj side Compare above but for jogging in the
wobj frame.

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6.3.3.27 JOINT_JOG

-2,17B-2*

3DUDPHWHU The following table contains the parameters that belong to the data group JOINT_JOG.
GHVFULSWLRQ

3DUDPHWHU 'HVLJQDWLRQRQ738 'HVFULSWLRQ

name Name Name of the JOINT_JOG data group.
(Max. 16 characters.)
joint_1 Group 1 down This parameter determines the text for the up/
down movement of the joystick for Group 1. It is
an integer with min. value -3 and max. value 3.
The sign alters the arrow direction. If set to 0,
the jog direction is disabled.
joint_2 Group 1 rot This parameter determines the text for the up/
down movement of the joystick for Group 1. It is
an integer with min. value -3 and max. value 3.
The sign alters the arrow direction. If set to 0,
the jog direction is disabled.
joint_3 Group 1 side This parameter determines the text for the up/
down movement of the joystick for Group 1. It is
an integer with min -3 and max 3. The sign
alters the arrow direction. If set to 0, the jog
direction is disabled.
joint_4 Group 2 down Same as joint_1 but for Group 2.
joint_5 Group 2 rot Same as joint_2 but for Group 2.
joint_6 Group 2 side Same as joint_3 but for Group 2.

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6.4.1 Introduction

7XQLQJ

,QWURGXFWLRQ

2YHUYLHZ The servo control parameters can be adjusted (tuned) to achieve the best possible motion
performance.
This section contains a complete description of how to tune the axes and is divided into fol-
lowing sections:
• 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 286. Details the complete procedure of
tuning the axes, including necessary preparations and references to more detailed
instructions of setting tuned values for the different parameters.
• Separate procedures that detail how to set the tuning parameters respectively.

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6.4.2 Tuning of axes, complete procedure

7XQLQJRID[HVFRPSOHWHSURFHGXUH

*HQHUDO This section contains the complete procedure for tuning the axes.
The specified parameters are in this section designated according to the configuration files
and are further detailed in the section 3DUDPHWHUGHVFULSWLRQ on page 254, which includes
description of the parameter and its designation on the TPU.

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

+RZWRVHWWKH When tuning the axes, the affected parameters are preferably set directly in the configuration
SDUDPHWHUYDOXHV file, with a text editor. The parameters may also be found on the TPU after performing a
service boot. (Press the button 0LVFDOOHQRXVand select 6\VWHPSDUDPHWHUV- Topic 0DQLSX
ODWRU- menu 7\SHV/DJFRQWUROPDVWHU.)
If the parameter values are set on the TPU, instead of directly in the files, they must later on
be exported and added to the original configuration files.

3UHSDUDWLRQV Following preparations must be made before tuning a servomotor axis:

• Set up the Test Signal Viewer software according to the instructions in the pdf-file 7HVW
6LJQDO9LHZHU, enclosed with the program.
• Make sure that the external axis is commutated and calibrated. Any position may be
defined as the calibration position.
• Select or use default tuning parameters so the axis may be jogged without stopping due to
speed or torque supervision.

7XQLQJFDOLEUDWHG Tuning a calibrated axis means setting values for several parameters in the data group LCM0.
D[HVRYHUYLHZ The procedure below is an overview of the complete tuning procedure and includes refer-
ences to more detailed instructions of how to actually set each parameter.

6WHS $FWLRQ
1. Make the 3UHSDUDWLRQV on page 286.
2. Locate the correct internal configuration file, open it in a text editor and modify the
values in the data group LCM0 as described in this procedure.
How to locate the file is detailed in the section )LOHKDQGOLQJ on page 305.
3. Set initially tuned values for the parameters Kv , Kp and Ti . This is further
detailed in the section ,QLWLDOWXQLQJRI.Y.SDQG7L on page 290.

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6.4.2 Tuning of axes, complete procedure

6WHS $FWLRQ
4. Set a value for the parameter ffw_mode (feedforward mode) by choosing one of
following modes:
• : This is the easiest configuration with no adjustments of the position lag.
(this mode is displayed on the TPU as 1R)
• : This is the recommended configuration. In this configuration the control-
ler receives information about the desired speed of the axis. As a result, the
position lag is greatly reduced compared to the configuration. (this mode
is displayed on the TPU as 6SG)
• : In this configuration the controller uses the desired speed and accelera-
tion of the axis to calculate the desired motor torque. This requires knowl-
edge of the mass moment of inertia of the axis, which must be supplied by
the user. For this reason this configuration is more difficult to tune, specially
for the axes affected by gravity. It is only recommended for experienced
users. (this mode is displayed on the TPU as 7UT)
The controller is driven by the position lag. This is the offset in time from the point
of given command til the point of actual performance of the command. The lag may
be adjusted with the different modes in the parameter ffw_mode .
Depending on which mode is chosen for the ffw_mode , different parameters and
values can further on be set.
5. Set a value for the parameter inertia , depending on chosen mode for the
ffw_mode
• ffw_mode 0 : set inertia to 0
• ffw_mode 1 : set inertia to 0
• ffw_mode 2 : calculate and set inertia according to the section 6SHF
LI\LQJWKHLQHUWLD on page 296.
6. If parameter ffw_mode is set to 1, the following parameters are also available:
• bandwith , should be left at its default value
• delay , should be left at its default value.
7. If parameter ffw_mode is set to 2, the following parameters are also available:
• bandwith , should be left at its default value. Adjustment is detailed in the
section 7XQLQJRIEDQGZLWK on page 297.
• delay , should be left at its default value (0.004). In rare cases, increasing
the value may reduce the speed overshot.
• resonance_frequency , should initially be left at its default value. May
be adjusted once the other parameters are set, if the WRUTXHBUHIsignal is
oscillatory due to mechancial resonance. How to tune this parameter is
detailed in the section 7XQLQJRIUHVRQDQFHBIUHTXHQF\ on page 298.
• resonance_damping , should be left at its default value (0.01).
8. Set tuned values for wc_acc (nominal acceleration) and wc_dec (nominal decel-
eration) in the data group ACC_DATA as detailed in the section 7XQLQJRIZFBDFF
DQGZFBGHF.
9. Set finally tuned values for the parameters Kv , Kp and Ti . This is further detailed
in the section )LQDOWXQLQJRI.S.YDQG7L on page 301.
10. Reload the edited configuration file to the controller. Further detailed in the section
)LQDODGMXVWPHQWV on page 309.

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6.4.2 Tuning of axes, complete procedure

7XQLQJXQFDOL Tuning an uncalibrated axis means setting values for several parameters in the data group
EUDWHGD[HVRYHU UCM0. The procedure below is an overview of the complete tuning procedure and includes
YLHZ references to more detailed instructions of how to actually set each parameter.

6WHS $FWLRQ
1. Make the 3UHSDUDWLRQV on page 286.
2. Set the initial tuning values of Kp , Kv and Ti . Use tuned values, set during tuning
of a calibrated axis. Use the values so that the axis is movable no matter of the
position.
3. Set the tuning value of speed_max_n (Speed max uncal). Maximum speed for
uncalibrated axis (rad/s on motor side).
4. Set the tuning value of dec_max_n (dec max uncal). Maximum deceleration for
uncalibrated axis (rad/s2 on motor side). Recommended value: nominal decelera-
tion * transm gear ratio. How to set the value for the nominal deceleration is detailed
in the section 7XQLQJRIZFBDFFDQGZFBGHF on page 299.
5. Set the tuning value of acc_max_n (acc max uncal). Maximum acceleration for
uncalibrated axis (rad/s2 on motor side). Recommended value: nominal accelera-
tion * transm gear ratio. How to set the value for the nominal acceleration is detailed
in the section 7XQLQJRIZFBDFFDQGZFBGHF on page 299.
6. Set the final tuning values of Kp , Kv and Ti , as detailed in the section )LQDOWXQLQJ
RI.S.YDQG7L on page 301.
7. Reload the edited configuration file to the controller. Further detailed in the section
)LQDODGMXVWPHQWV on page 309.

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6.4.3 Defining signals in Test Signal Viewer

'HILQLQJVLJQDOVLQ7HVW6LJQDO9LHZHU

'HILQLQJWHVWVLJ The Test Signal Viewer is used during tuning of the parameters. This section shows the sig-
QDOV nals that may be used, and how these are defined from the menu Commands - Define Test
Signal.

6LJQDOLGHQWLILHU Some of the signals may be defined from a drop down list as shown in the figure below:

en0400000763

- speed
- torque_ref

6LJQDOLGHQWLILHU Some of the signals may be defined manually by entering numbers as shown in the figure
PDQXDO below:

en0400000764

6 speed
9 torque_ref
55 positive torque_limit
56 negative torque_limit
57 torque feed forward

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6.4.4 Initial tuning of Kv, Kp and Ti

,QLWLDOWXQLQJRI.Y.SDQG7L

*HQHUDO This section details how to make the initial tuning of the parameters Kv , Kp and Ti .
The general strategy is to tune Kv first while keeping Kp constant and without integral effect
(Ti is set to a high value, e.g. 10), then tune Kp to its maximum value without vibration/
oscillation; finally tune Ti and other parameters.

1RWH
Check that the additonal axex motor file contains the correct motor data.

3DUDPHWHU The parameters Kv , Kp and Ti are found in the data group LCM0 and are further described
GHVFULSWLRQ in the section /&0 on page 281.

5$3,'SURJUDP Program a back-and-forth motion of the axis. For the final tuning of the control parameters
of the axis it is convenient to use the TuneServo command. Each procedure below includes
an example of a RAPID program that can be used.

,QLWLDOWXQLQJRI The procedure below details how to make the initial tuning of the parameter Kv , gain speed
.Y loop.

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

6WHS $FWLRQ
1. Set the parameter ffw_mode to 0 (No).
2. Make following changes in the internal configuration file, in data group LCM0:
• set the value of parameter Kp to 5
• set the value of parameter Ti to 10 (a big value in order to eliminate inte-
gral portion).
Load the edited configuration file to the controller.
Where to find the configuration file and how to load it is detailed in section )LQH
DGMXVWPHQWVLQFRQILJXUDWLRQILOHV on page 308

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6.4.4 Initial tuning of Kv, Kp and Ti

6WHS $FWLRQ
3. Increase the Kv value by 10% in each motion loop, until the axis starts to vibrate/
oscillate or a clear vibration can be heard from the axis, either during motion or
when stationary. The axis velocity supervision may also indicate speed failure.
The following RAPID program can be used to increase Kv by 10% of the default
value set in the loaded configuration file:
MODULE Kv_tune
PROC main()
VAR num i;
VAR num per_Kv;
VAR num Kv;

TuneReset;
FOR i FROM 0 TO 40 DO
per_Kv:=100+10*i;
Kv:=1*per_Kv/100;
TPErase;
TPWrite "per_Kv = "\Num:=per_Kv;
TPWrite "Kv = "\Num:=Kv;
TuneServo STN1,1,100\Type:=TUNE_KP;
TuneServo STN1,1,100\Type:=TUNE_TI;
TuneServo STN1,1,per_Kv\Type:=TUNE_KV;
MoveJ p1,v1000,z50,tool0;
MoveJ p2,v500,z50,tool0;
MoveJ p1,v1000,z50,tool0;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
1RWH The velocity data and test positions may be modified depending on the type
of robot and axis to be tuned.
The RAPID instructions are described in the 5$3,'5HIHUHQFHPDQXDO. Art. no. for
the manual is specified in the section 'RFXPHQWUHIHUHQFHV.
The 7RUTXHBUHIsignal in the Test Signal Viewer may be used to evaluate the degree
of vibration/oscillation. A typical plot of the signal is shown in the figure ,OOXVWUDWLRQ
WRUTXHBUHISORW on page 292.
4. Once an unstable point is reached, divide the current value of Kv by 2.
5. Enter the new value in the internal configuration file, as the initially tuned value for
Kv , and reload the file to the controller.

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6.4.4 Initial tuning of Kv, Kp and Ti

,OOXVWUDWLRQ How to choose the torque_ref signal in the Test Signal Viewer is detailed in section 'HILQLQJ
WRUTXHBUHISORW VLJQDOVLQ7HVW6LJQDO9LHZHU on page 289.

xx0400000644

A Normal plot
B Unstable plot

,QLWLDOWXQLQJRI The procedure below details how to make the initial tuning of the parameter Kp , gain posi-
.S tion loop.

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

6WHS $FWLRQ
1. Leave the initially tuned value of the parameter Kv and the earlier set default val-
ues of Kp and Ti unchanged.

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6.4.4 Initial tuning of Kv, Kp and Ti

6WHS $FWLRQ
2. Increase the Kp value by 10% in each motion loop, until the first signs of over-
shooting are observed in the velocity plot.
The following RAPID program may be used to increase Kp by 10% of the default
value set in the loaded configuration file:
MODULE kp_tune
PROC main()
VAR num i;
VAR num per_Kp;
VAR num Kp;

TuneReset;
FOR i FROM 0 TO 20 DO
per_Kp:=100+10*i;
Kp:=5*per_Kp/100;
TPErase;
TPWrite "per_Kp = "\Num:=per_Kp;
TPWrite "Kp = "\Num:=Kp;
TuneServo STN1,1,100\Type:=TUNE_KV;
TuneServo STN1,1,100\Type:=TUNE_TI;
TuneServo STN1,1,per_Kp\Type:=TUNE_KP;
MoveJ p1,v1000,z50,tool0;
MoveJ p2,v500,z50,tool0;
MoveJ p1,v1000,z50,tool0;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
1RWH The velocity data and test positions may be modified depending on the type
of robot and axis to be tuned.
The RAPID instructions are described in the 5$3,'5HIHUHQFHPDQXDO. Art. no. for
the manual is specified in the section 'RFXPHQWUHIHUHQFHV.
A typical plot with speed overshot in the Test Signal Viewer is shown in the figure
,OOXVWUDWLRQVSHHGSORW on page 294.
3. Once an overshot is observed, subtract 1 from the current value of Kp .
If an overshooting is observed at a later time, the Kp must be reduced to an even
lower value.
4. Enter this new value in the internal configuration file, as the initially tuned value for
Kp , and reload the file to the controller.

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6.4.4 Initial tuning of Kv, Kp and Ti

,OOXVWUDWLRQVSHHG How to choose the speed signal in the Test Signal Viewer is detailed in section 'HILQLQJ
SORW VLJQDOVLQ7HVW6LJQDO9LHZHU on page 289.

xx0400000648

A Normal plot
B Overshoot

,QLWLDOWXQLQJRI7L The procedure below details how to make the initial tuning of the parameter Ti , integration
time speed loop.

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

6WHS $FWLRQ
1. Leave the initially tuned values of parameters Kv and Kp unchanged.
2. Set the value of Ti to 1.0 as default and reload the configuration file to the con-
troller.

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6.4.4 Initial tuning of Kv, Kp and Ti

6WHS $FWLRQ
3. Reduce the Ti value by 10% in each motion loop, until an overshot is observed
on the velocity profile in the Test Signal Viewer.
Looking at the WRUTXHBUHIsignal can also help to determine the critical value of Ti .
The following RAPID program may be ued to reduce the Ti value by 10% of the
default value set in the loaded configuration file:
MODULE ti_tune
PROC main()
VAR num i;
VAR num per_Ti;
VAR num Ti;

TuneReset;
FOR i FROM 0 TO 10 DO
per_Ti:=100-10*i;
Ti:=1*per_Ti/100;
TPErase;
TPWrite "per_Ti = "\Num:=per_Ti;
TPWrite "Ti = "\Num:=Ti;
TuneServo STN1,1,200\Type:=TUNE_KV;
TuneServo STN1,1,250\Type:=TUNE_KP;
TuneServo STN1,1,per_Ti\Type:=TUNE_TI;
MoveJ p1,v1000,z50,tool0;
MoveJ p2,v500,z50,tool0;
MoveJ p1,v1000,z50,tool0;
WaitTime 1;
ENDFOR
ENDPROC
ENDMODULE
1RWH The velocity data and test positions may be modified depending on the type
of robot and axis to be tuned.
The RAPID instructions are described in the 5$3,'5HIHUHQFHPDQXDO.
Art. no. for the manual is specified in section 'RFXPHQWUHIHUHQFHVin the 3URGXFW
PDQXDOUHIHUHQFHLQIRUPDWLRQ.
4. Once an overshot is observed, stop reducing and instead increase the tuned value
by 5-10%, in order to remove the effect.
5. When the effect is removed, enter the new value in the internal configuration file and
reload the file to the controller.

5HVXOW The parameters Kv , Kp and Ti are now initially tuned. Continue with the tuning process as
described in next section. The complete tunig procedure is detailed in section 7XQLQJRID[HV
FRPSOHWHSURFHGXUH on page 286.

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6.4.5 Specifying the inertia

6SHFLI\LQJWKHLQHUWLD

*HQHUDO This section details how to specify the mass moment of inertia. (only recommended for expe-
rienced users)

3UHUHTXLVLWH The parameter ffw_mode must be set to the value 2 (Trq), in order to have use of inertia
. If ffw_mode is set to 0 or 1, the parameter inertia is not used, but should be set to 0
anyway.

6SHFLI\LQJWKH The procedure below details how to calculate the mass moment of inertia and how to enter
LQHUWLD the value to the configuration file.

6WHS $FWLRQ
1. The inertia is given by:
Inertia = Inertia axis / (Transm gear ratio)2 + Inertiamotor + Inertia brake
2. Enter this value for the parameter inertia in the internal configuration file, in data
group LCM0, and reload the file to the controller. How to load the file is detailed in
the section )LQHDGMXVWPHQWVLQFRQILJXUDWLRQILOHV on page 308.

5HVXOW The parameter inertia is now tuned. Continue with the tuning procedure.

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6.4.6 Tuning of bandwith

7XQLQJRIEDQGZLWK

*HQHUDO This section details how to set the tuned value for the parameter bandwith .

3DUDPHWHU The parameter bandwith is found in the data group LCM0 and is further detailed in the
GHVFULSWLRQ section /&0 on page 281.

,OOXVWUDWLRQVSHHG The figure below shows a typical plot in the Test Signal Viewer when tuning the parameter
RYHUVKRWEDQG bandwith .
ZLWKWXQLQJ

xx0400000652

7XQLQJRIEDQG The procedure below details how to tune the parameter bandwith .
ZLWK

6WHS $FWLRQ
1. Use properly tuned values for the parameters Kv , Kp and Ti .
2. Use the default value (25) for the parameter bandwith .
3. In order to verify and tune the default bandwith value, run a motion program to
see if the speed overshot occurs. If the overshoot is out of the tolerance, reduce
the value of bandwith under the system resonance frequency.
The system resonance frequency may not always be identified. Therefore the value
may be varying several times and it may be necessary to perform a check of the
speed overshoot and of the following error between command position and actual
position. Normally, the bigger the bandwith value, the smaller the following error.
A typical speed overshoot plot is shown in the figure ,OOXVWUDWLRQVSHHGRYHUVKRW
EDQGZLWKWXQLQJ on page 297

5HVXOW The parameter bandwith is now initially tuned. Continue with the tuning process described
in the next section, and in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page 286.

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6.4.7 Tuning of resonance_frequency

7XQLQJRIUHVRQDQFHBIUHTXHQF\

*HQHUDO This section details how to set the value of the parameter resonance_frequency .

3DUDPHWHU The parameter resonance_frequency is found in the data group LCM0 on the internal
GHVFULSWLRQ configuration file and is further detailed in the section /&0 on page 281.

7XQLQJRI The procedure below details how to tune the parameter resonance_frequency .
UHVRQDQFHBIUHTX
HQF\

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

6WHS $FWLRQ
1. Measure the distance between the resonance peaks (in points) on the plot of the
WRUTXHBUHI signal. Divide the sampling frequency with this value:
resonance_frequency = sampling frequency / distance between resonance
peaks
This calculation gives a rough estimate (in 1/s).
1RWH The sampling frequency of the logged data depends on the sampling interval
that has been selected in the configuration of the Test Signal Viewer.
2. The value of resonance_frequency should be in the range 3 to 25 (default 100).
To tune resonance_frequency , program a short back-and-forth motion of the
axis at maximum speed. The axis should not be allowed to reach full speed before
deceleration. Use the TUNE_DF argument of the TuneServo command to adjust
resonance_frequency and examine the WRUTXHBUHI signal.
Adjust resonance_frequency until the oscillations in the WRUTXHBUHI signal are
damped out.
3. Enter the tuned value of resonance_frequency to the configuration file and
reload it to the controller.

5HVXOW The parameter resonance_frequency is now tuned. Continue with the tuning procedure
as described in the next section, and in section 7XQLQJRID[HVFRPSOHWHSURFHGXUH on page
286.

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6.4.8 Tuning of wc_acc and wc_dec

7XQLQJRIZFBDFFDQGZFBGHF

*HQHUDO This section details how to make the tuning of the parameters wc_acc and wc_dec .

3DUDPHWHU The parameters wc_acc and wc_dec are found in the data group ACC_DATA and are
GHVFULSWLRQ further described in the section $&&B'$7$ on page 263.

3UHSDUDWLRQV The following preparations must be made before performing the tuning:
• If an axis has a varying moment of inertia, wc_acc and wc_dec should be tuned with the
maximum moment of inertia. For a description of how to specify the inertia see 6SHFLI\LQJ
WKHLQHUWLD on page 296.
• If gravity has an influence on the axis, then wc_acc should be tuned with a motion accel-
erating upwards gravity. wc_dec should be tuned with a stopping motion (deceleration)
while moving downwards in gravity direction.
• Program two test points for acceleration and two test points for deceleration with the fol-
lowing requirements:
• Velocity: choose a velocity that is approximately 50% of the maximum speed of the
external axis.
• Distance: the distance should be chosen to ensure that the axis stabilises at the pro-
grammed velocity before deceleration starts.

7XQLQJRIZFBDFF The procedure below details how to make the tuning of the parameters wc_acc and wc_dec
DQGZFBGHF .
Before beginning the tuning, observe the following warnings:

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

:DUQLQJ
Kp can affect the torque level (torque_ref). Therefore, acceleration/deceleration tuning
should be verified again if Kp is changed more than 10%.

:DUQLQJ
For low values of Kp (e.g. <5) the axis might never reach the acceleration/deceleration value
and these values can be tuned to unrealistically high values without reaching the torque limit.
This can cause problems during an emergency stop if brake_control_on_delay is >0 (motors
used at emergency stop). Do not continue to increase acceleration/deceleration if the effect
on WRUTXHBUHIis small. Always verify WRUTXHBUHI level at emergency stop.

6WHS $FWLRQ 1RWH

1. Use the Test Signal Viewer software to record the val- How to define these sig-
ues of SRVLWLYHQHJDWLYHWRUTXHBOLPLWand WRUTXHBUHI for nals is detailed in section
the axis. 'HILQLQJVLJQDOVLQ7HVW
6LJQDO9LHZHU on page
289.

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6.4.8 Tuning of wc_acc and wc_dec

6WHS $FWLRQ 1RWH

2. Use test positions for wc_acc and do as following:
1. Run the motion and check the value of
WRUTXHBUHIfor the SRVLWLYHQHJDWLYHWRUTXHBOLPLW.
2. Adjust the value of wc_acc upwards or down-
wards in increments of 0.5 until the WRUTXHBUHI
signal shows that the axis nears, but does not
reach the torque limit.
3. Reduce the final value by 10% to allow for varia-
tions in the mechanical system over a period of
time.
3. Use test positions for wc_dec and do as following:
1. Run the motion and check the value of
WRUTXHBUHIfor the SRVLWLYHQHJDWLYHWRUTXHBOLPLW.
2. Adjust the value of wc_dec upwards or down-
wards in increments of 0.5 until the WRUTXHBUHI
signal shows that the axis nears, but does not
reach the torque limit.
3. Reduce the final value by 10% to allow for varia-
tions in the mechanical system over a period of
time.

5HVXOW The parameters wc_acc and wc_dec are now tuned. Continue with the tuning process as
described in next section. The complete tuning procedure is detailed in section 7XQLQJRID[HV
FRPSOHWHSURFHGXUH on page 286.

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6.4.9 Final tuning of Kp, Kv and Ti

)LQDOWXQLQJRI.S.YDQG7L

*HQHUDO This section details how to make the final tuning of the parameters Kv , Kp and Ti .

3DUDPHWHU The parameters Kv , Kp and Ti are found in the data group LCM0 and are further described
GHVFULSWLRQ in the section /&0 on page 281.

3UHSDUDWLRQV The following preparations must be made before performing the final tuning:
• The parameters must be initially tuned as detailed in the section ,QLWLDOWXQLQJRI.Y.SDQG
7L on page 290
• If the axis has a varifying moment of inertia, the parameters Kv , Kp and Ti should be
tuned with the maximum value for the moment of inertia.
• Program two test points with the following requirements:
• Velocity: choose a velocity that is approximately 25% of the maximum speed of the
external axis. The speed must be low enough to guarantee that the axis does not
encounter the torque limit but high enough to prevent friction from affecting the result.
• Distance: choose a distance that ensures that the axis stabilises at the programmed
velocity before deceleration starts.

5$3,'SURJUDP The following RAPID program can be used during the final tuning of the parameters Kv , Kp
and Ti :
PROC main()
ActUnit STN1;
TuneServo STN1,1,TuneValue\Type:=TUNE_KP;
TuneServo STN1,1,TuneValue\Type:=TUNE_KV;
TuneServo STN1,1,TuneValue\Type:=TUNE_TI;
FOR i FROM 1 TO 10 DO
MoveJ p1,v_tune,fine,tool0;
MoveJ p2,v_tune,fine,tool0;
MoveJ p1,v_tune,fine,tool0;
ENDFOR
DeactUnit STN1;
ENDPROC
The argument TuneValue is a percentage (1-500) of the set value in the loaded configura-
tion file. 100% is the normal value.
Further descriptions of the RAPID instructions and arguments are found in the 5$3,'5HIHU
HQFHPDQXDO.
Art. no. for the manual is specified in section 'RFXPHQWUHIHUHQFHVin the 3URGXFWPDQXDO
UHIHUHQFHLQIRUPDWLRQ.

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6.4.9 Final tuning of Kp, Kv and Ti

,OOXVWUDWLRQILQDO The figure below shows the desired profiles of VSHHGand WRUTXHBUHIwhen making the final
WXQLQJRI.S tuning of the parameter Kp .
slight overshoot
VSHHG acceptable no overshoot
acceptable

WLPH

one or two damped

WRUTXHBUHI oscillations acceptable

WLPH

xx0400000649

)LQDOWXQLQJ The procedure below details how to make the final tuning of the parameters Kv , Kp and Ti .

:DUQLQJ
The system is unstable and therefore dangerous during the tuning process, since bad param-
eters or parameter combinations may be used! The safety procedures of the robot system must
be carefully followed throughout the tuning process.

6WHS $FWLRQ
1. Make the preparations detailed in the section 3UHSDUDWLRQV on page 301 before per-
forming the final tuning.
2. Use the initially tuned values of Kv , Kp and Ti as default values in the configu-
ration file, data group LCM0, and make sure the file is loaded to the controller.
3. Make a final tuning of the parameter Kv by using the 5$3,'SURJUDP on page 301
with following values:
• Increase the TuneValue for Kv in steps of 5% and observe the WRUTXHBUHI
in the Test Signal Viewer. Stop when the axis starts to vibrate/oscillate.
• Divide the TuneValue by 2 and run the axis again, while observing the
WRUTXHBUHI. There should be at most one or two damped oscillations after
the acceleration stage. If WRUTXHBUHI oscillates more than this, decrease its
value somewhat.
Kv is a critical parameter. A large value will result in a stiff axis and a fast response.
If Kv is too small, Kp will also be limited, resulting in an under-utilised axis.
4. Make a final tuning of the parameter Kp by using the 5$3,'SURJUDP on page 301
and following information:
• Increase the TuneValue for Kp slowly until the desired VSHHGand
WRUTXHBUHIprofiles are achieved as shown in the figure ,OOXVWUDWLRQILQDOWXQ
LQJRI.S on page 302. The position error (lag) is inversely proportional to
Kp thus a large value for Kp is desirable.

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6.4.9 Final tuning of Kp, Kv and Ti

6WHS $FWLRQ
5. Make a final tuning of the parameter Ti by using the 5$3,'SURJUDP on page 301
with following values:
• Reduce the TuneValue for Ti in steps of 5% until the effect can be seen
on the plot of VSHHG as an increased overshoot.
• Increase the TuneValue for Ti by 5-10% until the effect is removed.
6. Calculate the final values of Kv , Kp and Ti by multiplying the initially tuned value
in the configuration file (that was used as the default value) by the given
TuneValue divided by 100.
Default value * (TuneValue / 100)
7LSThe default value may also be found on the TPU as detailed in the section +RZ
WRVHWWKHSDUDPHWHUYDOXHV on page 286.
7. Enter these new values for Kv , Kp and Ti in the configuration file, data group
LCM0, and reload the file to the controller.
How to find the configuration file and how to load it is detailed in the section )LQH
DGMXVWPHQWVLQFRQILJXUDWLRQILOHV on page 308.

5HVXOW The parameters Kv , Kp and Ti are now finally tuned.

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6.5.1 Introduction

)LOHKDQGOLQJFRQILJXUDWLRQDQGHUURUPDQDJHPHQW

,QWURGXFWLRQ

2YHUYLHZ
This section details how to
• locate and handle the configuration files
• use a Hyper Terminal
• find and correct errors in the configuration.

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6.5.2 File handling

)LOHKDQGOLQJ

*HQHUDO This section details how to handle the configuration files that are edited with configuration
data.
The modifications are made in three steps:
• basic modifications to the parameters in the configuration files
• fine adjustments to the parameters in the configuration files
• final adjustments (restorage and saving).

)LOHVWUXFWXUHRQ After installing the RobotWare CD-ROM, the file structure shown below is created on the PC.
3&KDUGGULYH The modifications to the configuration data are made in the configuration files.
The figure below shows the path to the configuration files of IRC S4Cplus. (C:\Program
Files\ABB Robotics\MediaPool\3HAC6811-x.xx\robots\s4c_irc\irccfg). The path may differ
depending on what folders have been pointed out during the installation of the RobotWare
CD-ROM.
In the folder "MediaPool", all software releases are represented with a folder, named as the
software. In the figure the software folder 3HAC6811-1.92 is pointed out as an example. The
folder is later designated +$&  .

3HAC 021333-001 A 305

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6.5.2 File handling

xx0300000634

In the folder "robots", the configuration files are divided into folders named after a specific
robot system. For the IRC S4Cplus, the configuration files are located in the folder "s4c_irc".
For each kinematic model there are three configuration files, named after the designation of
the model but without parentheses. In the figure the model X_Y_Z_B(X) is pointed out as an
example. This designation is later simply mentioned with an asterisk (*).
• configuration file: BHFIJ. This is the external configuration file. It can be edited by
the user, either in a text editor or on the TPU.
• configuration file: BLFIJ. This is the internal configuration file. It must be edited in a
text editor by an integrator, but can also be shown on the TPU.
• configuration file: BVFIJ. This is a an encrypted configuration file that cannot be
modified.

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6.5.2 File handling

%DVLFDGMXVW The procedure below details how to handle the configuration files when editing them before
PHQWVLQFRQILJX the first installation of the system.
UDWLRQILOHV

6WHS $FWLRQ 1RWH

1. Install the RobotWare CD-ROM. Detailed in section
5RERW:DUH&'520
on page 147.
2. The Read-only folder "3HAC6811-x.xx" must be given write The HyperTerminal is
permission. This is done according to the instruction below. further detailed in the
(x.xx signifies the software release) section +RZWRXVHD
• Open a HyperTerminal on the PC in order to communi- +\SHU7HUPLQDO on
cate with the file structure of the robot system. A stan- page 310.
dard application in Windows may be used, it is found at: The path to the folder
Start / Programs / Accessories / Communications / is shown in the figure
HyperTerminal. )LOHVWUXFWXUHRQ3&
• Navigate to the current software folder, "3HAC6811- KDUGGULYH on page
x.xx", using UNIX commands. 305.

• Type %RRWVXS52UHVHW+$&[[[ and press

ENTER. (x.xx signifies the current software release)

3. Locate the configuration files on the PC hard drive. The path is shown in
the figure )LOHVWUXF
WXUHRQ3&KDUGGULYH
on page 305.
4. Choose the correct configuration files, depending on which The different kine-
kinematic model is chosen for the robot system. matic models are
detailed in the section
.LQHPDWLFPRGHOV on
page 224.
5. Open two of the three configuration files: the BHFIJand
the BLFIJ in a text editor, e.g. Notepad.
6. Edit the configuration files with desired values. The configuration
parameters are
detailed in the section
3DUDPHWHUGHVFULSWLRQ
on page 254.
7. Save and close the modified configuration files.

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6.5.2 File handling

6WHS $FWLRQ 1RWH

8. When changing the parameters, the system normally needs
to be rebooted for the parameters to take effect. This may
be avoided if the file ,QVWDOOFPG is modified as detailed
below:
• Open the file ,QVWDOOFPG with a text editor. The file is
located in the folder "s4c_irc".
• Locate the command lines for the specific configuration
files of the chosen kinematic model, shown in the figure
below.
• Find the line for the configuration file: BLFIJ and delete
"-internal".

xx0300000635

9. Install the modified system to the controller with RobInstall. Detailed in the section
&UHDWHDQHZ5RERW
&RQWUROOHU6\VWHP on
page 150.
10. If further adjustments are necessary, proceed with the
instruction )LQHDGMXVWPHQWVLQFRQILJXUDWLRQILOHV on page
308.
If the system is ready for operation, make the final adjust-
ments detailed in )LQDODGMXVWPHQWV on page 309.

)LQHDGMXVWPHQWV The procedure below details how to handle the configuration files/folders when making addi-
LQFRQILJXUDWLRQ tional modifications after the basic adjustments detailed above. Repeat the procedure as many
ILOHV times as necessary until the robot system is ready for operation.

6WHS $FWLRQ 1RWH

1. Locate the configuration files on the PC The path is shown in the figure )LOHVWUXF
hard disk. WXUHRQ3&KDUGGULYH on page 305.
2. Make the necessary modifications in Tuning is detailed in the section 7XQLQJRI
the configuration files. D[HVFRPSOHWHSURFHGXUH on page 286.
The configuration parameters are detailed
in the section &RQILJXUDWLRQ on page 241.
3. Open the FTP Client on the PC. The FTP Client is delivered with the
RobotWare CD-ROM. The installation is
detailed in the section 5RERW:DUH&'
520 on page 147.
4. Load the modified configuration files to
the corresponding file structure on
hd0a:// in the controller.
5. Repeat the steps above until the robot
system is ready for operation.
When the system is ready, make the
final adjustments described in the next
section.

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6.5.2 File handling

)LQDODGMXVWPHQWV Before the system is ready for operation, the final adjustments detailed in the procedure below
must be performed.

6WHS $FWLRQ 1RWH

1. Restore the ,QVWDOOFPG in the folder "s4c_irc" by writing back
the data "-internal" as shown in the figure below:

xx0300000635

2. Turn back the Read-only protection to the software folder

"3HAC6811-x.xx" with the command: %RRWVXS52VHW
+$&[[[ in the HyperTerminal application.
3. Make a copy of the complete software folder "3HAC6811-x.xx",
preferably by burning it onto a CD.
1RWH It is extremely important that the robot system user always
has access to a copy of the modified configuration files, since
these are not automatically saved as a back-up in the system!

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6.5.3 How to use a Hyper Terminal

+RZWRXVHD+\SHU7HUPLQDO

*HQHUDO This section details how to connect the robot system to a Hyper Terminal. A Hyper Terminal
is a software used to log the communication between the controller and the PC.

+RZWRXVHD
+\SHU7HUPLQDO
6WHS $FWLRQ
1. Connect the PC to the controller. Use the MC/CONSOLE port in the controller and
the COM1 port in the PC.
The MC/CONSOLE is further described in the section &RPPXQLFDWLRQVHULDOOLQNV
on page 135.
2. Open a Hyper Terminal application.
A Microsoft Windows application may be used: Start / Programs / Accessories /
Communications / HyperTerminal.
3. Use UNIX commands to navigate in the software.

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6.5.4 Error management

(UURUPDQDJHPHQW

*HQHUDO This section details how to handle the fault localization after performing the system configu-
ration.
The fault localization is made in following steps:
1. start the Hyper Terminal to get access to the log file containing information about the
communication between the controller and the PC
2. check the log file and search for faults
3. edit the file *_i.cfg (the internal configuration for the kinematic model in question)
4. reload the configuration file
For a description of how to use a Hyper Terminal see the section +RZWRXVHD+\SHU7HUPLQDO
on page 310.

+DQGOLQJHUURUV Fault localization is an iterative process that must go on until all errors are eliminated. The
DQLWHUDWLYHSUR following steps describe the order of the process:
FHVV

6WHS 'HVFULSWLRQ
1. Search for error messages in the log file. Identify the first error in the file. Status 0
implies that the file is found and the operation has passed. A negative status value
implies that an error has occured.
For an example of the status information see illustration in the section ,OOXVWUDWLRQRI
HUURUPHVVDJHVLQORJILOH below.
2. Open the configuration file (internal or external configuration file) and correct the
first error that was found in the log file. The illustration below shows a part of an
internal configuration file.
1RWHTo avoid new error messages only correct one error at a time.
3. Save the edited configuration file and load the file to the controller. Further details
are in the section )LQHDGMXVWPHQWVLQFRQILJXUDWLRQILOHV on page 308.
4. Make an I-start, i.e a cold start of the system.
5. Go back to step 1 and proceed with the four steps above until all errors are elimi-
nated.

,OOXVWUDWLRQRI The figure below shows an example of the contents of the log file.
HUURUPHVVDJHVLQ
ORJILOH

en0400000683

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6.5.4 Error management

([DPSOHVRIHUURU The table below gives some examples of common error messages that can show up in the log
PHVVDJHV file after system configuration.

'HVFULSWLRQFDXVHRI
(UURUPHVVDJHLQORJILOH +RZWRFRUUHFWWKHHUURU
IDLOXUH
04-01-13 16:33:46 MC0: With regard to hardware Check the hardware and set
param.c 1286 drive unit position and the correct node values for the
cfg_get_named_instance for node position; do not exist parameter use_drive_unit
’DRIVE_UNIT’ ’unit2_node2’ for axis irc_2. , in the X_Y_Z_i.cfg file. The
failed. parameter is described in the
section '5,9(B6<67(0 on
page 272.
04-01-13 17:43:59 MC0: In this case, the sign for the Check the lines for missing or
cfg_file.c 2142 line breaking, "\", is miss- incorrect signs.
Mandatory attribute ’name’ ing on line 179 in the
missing in line 180 X_Y_Z_i.cfg file.
Status -13 from config compr:/ The error message indi-
hd0a/3HAC6811-1.81/robots/ cates that the error exists
s4c_irc/irccfg/X_Y_Z_i.cfg in some of the lines before
line 180.
04-01-13 17:50:57 MC0: type = The value of pole_pairs (in Change the value of the
ERROR id = SYSTEM code = this case, on line 179) in parameter pole_pairs in
136 the X_Y_Z_i.cfg file is not the X_Y_Z_i.cfg file. The
arg 0: pole_pairs within the permitted limits. parameter and permitted limits
arg 1: 180 The error message indi- are described in the section
cates that the error exists 02725B7<3( on page 275
Status -12 from config compr:/
hd0a/3HAC6811-1.81/robots/ in the parameter
s4c_irc/irccfg/X_Y_Z_i.cfg pole_pairs , in some of
the lines before line 180.

6XPPDU\ Error management is necessary to secure that the correct files are used, i.e. the right configu-
ration file for a certain kinematic model. It is also important to check that the parameter
setting is done with correct/allowed values.
Everytime a new system configuration is done or axes are tuned, fault localization and error
correction must also be done to ensure that all errors are eliminated.

312 A 3HAC 021333-001

 ,QGH[

3HAC 021333-001 313

,QGH[

314 3HAC 021333-001

 3HAC 021333-001, Revision A, en

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Robotics
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