Product Manual

Control Cabinet
504 868-102
2003-10 M2001
The information in this document is subject to change without notice and should be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this document.

In no event shall ABB be liable for damages of any nature from the use of this document.

This document and parts thereof must not be reproduced or copied without ABB´s written
permission, and the contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose.

Copies of this document can be ordered from ABB.

© ABB Automation Technology Products AB

Artikelnummer: 504 868-102

Datum: 2003-10

ABB Automation Technology Products AB

Arc Welding & Application Equipment

S-695 82 Laxå

Sverige
 Control Cabinet

LIST OF CONTENTS
Page

1 General ......................................................................................................................... 5
1.1 Types of robot .................................................................................................... 5

2 Description of the top cabinet .................................................................................... 7

2.1 Structure............................................................................................................. 7
2.2 Connections ....................................................................................................... 8
2.3 Customer connections........................................................................................ 10
2.4 Option - Extended emergency stop.................................................................... 11
2.5 Option - Pivot frame .......................................................................................... 12
2.6 Safety/Directives and Standards ........................................................................ 13
2.7 ReservdelsförteckningSpare Parts List .............................................................. 13

3 Manipulator interface ................................................................................................. 19

3.1 Connections ....................................................................................................... 20
3.2 Drive system ...................................................................................................... 21
3.3 Drive unit ........................................................................................................... 23
3.4 Measurement system.......................................................................................... 25
3.5 Axis selector ...................................................................................................... 28
3.6 Positioner interface Type S (Fixed table) Single/double Station ....................... 31
3.7 Interface for conveyor type S (option)............................................................... 31
3.8 Reservdelsförteckning/Spare Parts List ............................................................. 34
3.9 Positioner interface type IRBP C/C Index ......................................................... 39
3.10 Reservdelsförteckning/Spare Parts List ............................................................. 42
3.11 Positioner interface type IRBP L/T ................................................................... 47
3.12 Reservdelsförteckning/Spare Parts List ............................................................. 49
3.13 Positioner interface types IRBP R/K/E/F .......................................................... 59
3.14 Reservdelsförteckning/Spare Parts List............................................................. 62
3.15 Positioner interface types IRBP B/D ................................................................. 69
3.16 Reservdelsförteckning/Spare Parts List............................................................. 72
3.17 Positioner interface types IRBP A ..................................................................... 79
3.18 Reservdelsförteckning/Spare Parts List ............................................................. 81

4 Interface for process equipment ................................................................................ 89

4.1 General............................................................................................................... 89
4.2 System design .................................................................................................... 90
4.3 Connection ......................................................................................................... 92
4.4 No process equipment - Jumper device NO AW ............................................... 93

504 868-102 3
Control Cabinet

4.5 Spare Parts List .................................................................................................. 95

4.6 Power source LAW/RPA/OEM.......................................................................... 99
4.7 Spare Parts List .................................................................................................. 106
4.8 MILLER............................................................................................................. 111
4.9 Spare Parts List .................................................................................................. 119
4.10 Power source ARCITEC-LRB........................................................................... 125
4.11 Spare Parts List .................................................................................................. 133
4.12 Power source ARCITEC-LRC........................................................................... 139
4.13 Spare Parts List .................................................................................................. 147
4.14 Power source ARCITEC-LRB ALUMINIUM .................................................. 153
4.15 Spare Parts List .................................................................................................. 161

5 Interface for operator communications and safety .................................................. 169

5.1 General ............................................................................................................... 169
5.2 System solutions ................................................................................................ 171
5.3 Connections........................................................................................................ 173
5.4 Operator communications for positioner types C/R/K ...................................... 175
5.5 Connection instructions...................................................................................... 181
5.6 Reservdelsförteckning/Spare Parts List ............................................................. 219
5.7 Operator communication for positioner types A/L/S......................................... 223
5.8 Connection instructions...................................................................................... 229
5.9 Spare Parts List .................................................................................................. 267
5.10 No safety equipment .......................................................................................... 271
5.11 Reservdelsförteckning/Spare Parts List ............................................................. 275

6 Technical Data.............................................................................................................. 279

7 Installation and set-up................................................................................................. 281

7.1 Transport and unpacking.................................................................................... 281
7.2 Lifting instructions ............................................................................................. 281
7.3 Mechanical installation ...................................................................................... 282
7.4 Connections........................................................................................................ 282
7.5 Check before start up ......................................................................................... 282
7.6 Start up ............................................................................................................... 283

8 Maintenance................................................................................................................. 285

4 504 868-102
 Control Cabinet
General

1 General

1.1 Types of robot

The top cabinet for equipment from the standard product range is adapted for
connection to the control system S4Cplus.
Please refer to the Product and User Guide for
a description of the control system
The product range has been produced for robot types:
- IRB 140/1400/2400 in AW design.
However, some products can, without further modification, be connected in
combination with other robot types.

504868-02_en.fm 5
Control Cabinet
General

6 504868-02_en.fm
 Control Cabinet
Description of the top cabinet

2 Description of the top cabinet

2.1 Structure
The Control Cabinet consists of the following units:

1 Control system S4Cplus

2 The top cabinet, which is available in two heights 620 mm/ 820 mm, with
interfaces for:
- positioner
- process equipment
- Operator communications and safety equipment

3 Welding power source ARCITEC LRB (if applicable)

Top cabinet

Programming unit

Control system S4Cplus

Power source LRB

Cabinet_S4Cplus-8

Figure 1 Control Cabinet

504868-02_en.fm 7
Control Cabinet
Description of the top cabinet

2.2 Connections

2.2.1 External connections

The figure below shows the external connections on the left of the top cabinet.

Connection Connection
Manipulator Safety
equipment

Connection
Conveyor Connection
Process
equipment

Connection
Operator
panel
Connection
External
welding power
source
Cabinet_S4Cplus-7

Figure 2 Connections

The interface modules in the top cabinet are connected to the control system via
a signal interface that distributes the requisite system signals and feeds.
Connections to the different units are made using jackable terminals to facilitate
service and repair work.

8 504868-02_en.fm
 Control Cabinet
Description of the top cabinet

2.2.2 Inside the top cabinet with component interface modules.

The figure below shows the inside of the top cabinet.
skå[Link]

    
Figure 3 Top cabinet, inside

1 Customer connections 4 OpCom interface

2 Positioner interface 5 Process interface

3 Option, Extended emergency stop

504868-02_en.fm 9
Control Cabinet
Description of the top cabinet

2.2.3 Extra customer space in the top cabinet

Extra customer space is only available in the high top cabinet (820 mm)

1
1 1
504049A01

Figure 4 Extra customer space in the top cabinet 820 mm

2.3 Customer connections

As standard the following signals and feeds are available on jackable terminals
to allow the addition of customer specific equipment:
Terminal A204-X1 24V I/O (DC) max 2A
Terminal A204-X2 Contactor/relay control via "MOTORS ON"
Two channel function control
Terminal A204-X3 Two channel connection for emergency stop device
Terminal A204-X4 CAN-bus connection
If the "Extended emergency stop" option is included the following signals are also
available:
Terminal A204-X5 Two channel contactor/relay control via "EMSTOP"
Two channel function control of contactor/relay control
as above
See Figure 3 for customer connections.

10 504868-02_en.fm
 Control Cabinet
Description of the top cabinet

2.4 Option - Extended emergency stop

Some installations require more emergency stop signals from the control system
than are available in the standard design. This applies, for example, when
emergency stop functions are required to be integrated in fixture control or
distributed to external equipment. This option offers a possibility of connecting
an optional number of redundant relays as required. See Figure 3

504868-02_en.fm 11
Control Cabinet
Description of the top cabinet

2.5 Option - Pivot frame

A pivot frame is available as an accessory to top cabinet 620/820.
The pivot frame is fitted to the left-hand end of the top cabinet door opening.
On the inside of the pivot frame space is provided for the installation of further
equipment and components.

2 3

Figure 5 Pivot frame (option)

1 Frame section 3 Transport locking device

2 Lock

12 504868-02_en.fm
 Control Cabinet
Description of the top cabinet

2.6 Safety/Directives and Standards

The electrical equipment is designed to comply with applicable demands, for
further information, see "Introduction and safety", chapter "Declaration",
under tab 1.

2.6.1 Safety categories

Equipment for safety has been designed so that safety functions are maintained in
the event of individual faults, such as a sticking relay, in the supervision system.
Faults are detected at the latest with the next call to the safety function.
This corresponds with category 4 in accordance with EN 954-1, Safety of
machinery, Control safety, Safety related parts of control systems. Part 1:
General principles for design.
For other parts of the control system please refer to
- the Product Manual for IRB 140/1400/2400.

2.7 ReservdelsförteckningSpare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

504868-02_en.fm 13
Control Cabinet
Description of the top cabinet

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11 502 146-001 Skåp Cabinet 620 mm

41 502 282-880 Huvudkabelstam Cable harness M2001
42 502 285-880 Kabelstam, Op-panel Cable harness, Op-panel
43 502 796-880 Canbus Canbus
44 503 172-880 Byglingsdon Clamping unit

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 Control Cabinet
Description of the top cabinet

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Description of the top cabinet

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11 502 145-001 Skåp Cabinet 820 mm

41 502 282-880 Huvudkabelstam Cable harness M2001
42 502 285-880 Kabelstam, Op-panel Cable harness, Op-panel
43 502 796-880 Canbus Canbus
44 503 172-880 Byglingsdon Clamping unit

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 Control Cabinet
Description of the top cabinet

11

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504868-02_en.fm 17
Control Cabinet
Description of the top cabinet

18 504868-02_en.fm
 Control Cabinet
Manipulator interface

3 Manipulator interface
There is a modular based interface fitted to the left of the cabinet’s rear panel for
the positioner. This may be equipped differently from case to case, depending on
the type of manipulator.

4
[Link]

Figure 6 Top cabinet, inside

1 Distribution contactor drive unit connection

2 Motor contactors with interface relay and auxiliary contact blocks for the
manipulator axis

3 Dig. I/O card

4 Terminal block for internal wiring

5 Serial measurement board

6 Auxiliary relay for brake activation

The interface is fitted with internal wiring for connection to the robot control
system. See Figure 6.

504868-03_en.fm 19
Control Cabinet
Manipulator interface

3.1 Connections
Cables to external equipment are connected to the outputs on the left-hand side of
the top cabinet.

2
Output 2

Figure 7 Terminations - positioner

1 Positioner

2 Travel track motor/resolver

20 504868-03_en.fm
 Control Cabinet
Manipulator interface

3.2 Drive system

3.2.1 Axis computer

Control cabinet S4Cplus is equipped wit an axis computer for the robot (axis
computer 1) and an axis computer card for the manipulator IRBP (axis computer 2).
Connection to the drive unit and serial measurement board is made via a connector
card. Each axis computer has its own connector card. See Figure 8.
Axis computer 1 6 axes for the robot (+ 1 external axis)
Axis computer 2 Up to 6 axes for the manipulator
Each axis computer has two drive systems (DS1 and DS2) and two measurement
systems (MS1 and MS2)

Axis computer 1
Drive system 1 (DS1) Drive unit for the robot
Drive system 2 (DS2) Rectifier or Rectifier + a drive unit for the positioner/
conveyor

Axis computer 2
Drive system 1 (DS1) Drive unit for manipulator and/or conveyor
Drive system 2 (DS2) Rectifier or Rectifier + a drive unit for the positioner.
(Only used when the multi-axes IRBP positioner is included in the system, moved
over from drive system 2 on axis computer 1)

Connector
card 1 Connector
card 2
Cabinet_S4Cplus_3

Figure 8 Connector card top cabinet

504868-03_en.fm 21
Control Cabinet
Manipulator interface

In order to control positioner IRBP the control cabinet must be ordered with
ABB Robotics’ option 397 "Prepared for external axes".
Option 397 contains the following components:
- Transformer T4
- Rectifier DC4 including a U type drive unit
- Axis computer 2
- Connector card 2

22 504868-03_en.fm
 Control Cabinet
Manipulator interface

3.3 Drive unit

The control cabinet for IRB140/1400 and 2400 can be equipped with max three
drive units for the positioner and/or robot carrier.
The control cabinet for IRB4400 and 6400 can be equipped with max one drive
unit for the positioner and/or robot carrier.
On delivery the control cabinet is equipped with drive units for the robot and
positioner axes included in the system.

Drive unit bay 0

Drive unit bay 3
Drive unit bay 2
Drive unit bay 1
Cabinet_S4Cplus_1

Figure 9 Drive unit positions in the top cabinet

or A B C

DC4
DC4 G/U
U

Drive unit Robot IRB140/1400/2400

IRB 140/1400 DC0

IRB1400H/IRB2400 DC1
IRB 4400 DC2
IRB 6400 DC4 Drive
Drive equipped

0 3 2 1

Drive unit Robot IRB4400/6400

Figure 10 Drive unit

504868-03_en.fm 23
Control Cabinet
Manipulator interface

Drive unit set-up for robots IRB 140/1400/2400

The following drive unit set-ups are available for robots IRB140/1400/2400 with
manipulator IRBP: See Figure 9.

Position 0 Position 3 Position 2 Position 1

B Empty Robot Robot

B C Robot Robot

Drive unit set-up for robots IRB 4400/6400

The following drive unit set-up is available for robots IRB 4400/6400 with
manipulator IRBP: See Figure 9.

Position 0 Position 3 Position 2 Position 1

B Robot Robot Robot

24 504868-03_en.fm
 Control Cabinet
Manipulator interface

3.4 Measurement system

Each axis computer has two measurement systems. A measurement system
can handle up to 7 axes.
Serial measurement boards are connected to the measurement system.
These include six nodes for connection of the resolvers.

3.4.1 Axis computer 1

Measurement system 1 (MS1) Serial measurement board for the robot
Measurement system 2 (MS2) Spare

Measurement
system 2

Drive system 2

Measurement
connector card 1

system 1

Drive system 1

Figure 11 Axis computer 1

504868-03_en.fm 25
Control Cabinet
Manipulator interface

3.4.2 Axis computer 2

Measurement system 1 (MS1) Spare
Measurement system 2 (MS2) Serial measurement board for manipulator/conveyor

Drive system 1
Drive system 2

Measurement system 2

Measurement system 1
connector card 2

Figure 12 Axis computer 2

26 504868-03_en.fm
 Control Cabinet
Manipulator interface

3.4.3 Resolver connection

The robot’s/manipulator’s axes are equipped with a resolver integrated with
respective motors to give exact positioning. See Figure 14
The resolvers are connected to the measurement channel for respective axis on the
serial measurement boards.

Serial
measurement
board
skå[Link]

Figure 13 Top cabinet - serial measurement card

AC-motor

Resolver
Skåp_S4Cplus_6

Figure 14 Motor with resolver

504868-03_en.fm 27
Control Cabinet
Manipulator interface

3.5 Axis selector

Up to 6 axis for the robot carrier and/or the manipulator can be connected to the
robot system.
The motor for these products can be connected to the robot system according to the
following options:

1 Direct drive between the motors and the drive units.

Robot carrier, station switching unit and some IRBP positioners (for
example, FlexArc Compact).

2 Motors connected via the motor contactors to the drive units.

Normal connection of the work stations for the IRBP positioner.
The drive unit can be used according to the following options:

1 Common drive unit. Two or more motors share a drive unit.

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DC4
3&

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Out a Out b
Axis Computer 1

Axis Computer 2

60%
M R M R

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Figure 15 Common drive unit

28 504868-03_en.fm
 Control Cabinet
Manipulator interface

2 Individual drive unit, i.e. one drive unit per motor (axis).

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DC4 U
3&

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Axis Computer 1

Axis Computer 2

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Figure 16 Individual drive unit

When direct connection is used, the connected axis follows the robot’s status with
activation/deactivation.
The motor connectors included in the axis selector are activated/deactivated by
signals from a digital I/O-card.

504868-03_en.fm 29
Control Cabinet
Manipulator interface

30 504868-03_en.fm
 Control Cabinet
Positioner interface

3.6 Positioner interface Type S (Fixed table) Single/double Station

Between the control system and the included positioner there is a modular based
interface fitted on the left of the top cabinet’s rear panel .

2
504070a01-2

1 Digital I/O card

2 Signal connection
This equipment is intended for installations with welding tables and therefore
contains no drive or measurement systems to control the motor axes.

Station indication (applies for FlexArc Compact C and S)

In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, where applicable, that indicate which station is in
the working mode for the robot.
The switches are cross-connected and actuate individual digital inputs in the
control system. Respective inputs are set “high” when the station changer unit is at
an end position.

3.7 Interface for conveyor type S (option)

Between the control system and the included manipulator there is a modular based
interface fitted to the left of the cabinet's rear panel.

504070-01_en.fm 31
Control Cabinet
Positioner interface

1
4

3
5
504744c01-2

1 Connection A0.2 Motor Positioner (fitted to output XS103) on the cabinet

wall’s output side

2 Digital I/O card

3 Signal connection

4 Communication cable (MS2) connection

5 Serial measurement board

32 504070-01_en.fm
 Control Cabinet
Positioner interface

1
504744a01-3

1 Rectifier with the drive unit, DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC 4
• Drive unit U (included in the rectifier module)
• Motor connection cable
A thermal contact for temperature monitoring is fitted to the manipulator's motor
to provide protection against overheating. This signal is connected to the control
system's PTC-loop.

Measurement system
For this positioner the measurement system consists of:
• Axis computer 2/connector card
• Communication cable (MS2)
• Serial measurement board
• Resolver connection cable

504070-01_en.fm 33
Control Cabinet
Positioner interface

Axis selector
The manipulator’s axle is permanently connected to the drive unit and
consequently follows the operating status of the robot with activation/deactivation.

Connecting the manipulator

The motor and resolver signals are gathered in a common output XS103 on the
control cabinet and the manipulator is connected to this output.

3.8 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

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Stationary och FlexArc Staionary and FlexArc
compact S/C Compact S/C

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15 501 112-001 Digitalt I/O-kort Digital I/O-board
16 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
17 500 958-001 Insticksbrygga Address Key 7-pol

23 489 947-601 Anslutningsdon, Combi- Connector, CombiCon 24 V

Con
24 489 947-603 Anslutningsdon, Combi- CombiCon 24 V
Con
41 504 165-880 Kabelstam S Cable harness S FlexArc Comp.

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 Control Cabinet
Positioner interface

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504070-01_en.fm 35
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Positioner interface

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504 744-880 Åkbana RTT, S/FlexArc Travel track RTT, S/Flex- M2001
Compact L/T Arc Compact L/T

13 502 341-881 Kabel Cable W217

15 193 715-110 Sockel Housing 64-pol
16 193 715-607 Ram Frame A-F
24 193 715-152 Kåpa Hood

25 193 715-151 Delad kåpa, max 4 kablar Shared hood, max 4

cables
31 505 966-880 Seriemätkort, kompl. Serial measurement SMB
board, compl,
31.1 505 966-001 Seriemätkort Serial measurement
board
31.5 505 966-003 Batterienhet Battery unit

37 502 511-880 Kabel Cable W230

38 500 157-001 Skärmklämma Screen clamp 6-16 mm
39 489 947-443 Anslutningsdon,Combi- Connector, CombiCon 4-pol
Con
41 504 159-880 Kabelstam, option Cable harness, option

42 502 508-880 Kabel Cable W233

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 Control Cabinet
Positioner interface

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504070-01_en.fm 37
Control Cabinet
Positioner interface

38 504070-01_en.fm
 Control Cabinet
Positioner interface

3.9 Positioner interface type IRBP C/C Index

Between the control system and the included positioner there is a modular based
interface fitted on the left of the top cabinet’s rear panel .

6
1
7

4
10
504071C01-2

1 Connection X7, Motor - Positioner

2 Resolver connection

3 Digital I/O card

4 Signal connection

5 Motor connector K15

6 Brake relay

7 Adapter X4

8 Safety signals, connection TB2

9 Communication cable (MS2) connection

10 Serial measurement board

504071-01_en.fm 39
Control Cabinet
Positioner interface

1
504071a01-3

1 Rectifier with the drive unit, DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC4
• Drive unit U (included in the rectifier module)
• Cables for connecting the motor
A thermal contact for temperature monitoring is fitted to the manipulator's motor to
provide protection against overheating. This signal is connected to the control
system's PTC-loop.

Measurement system
For this positioner the measurement system consists of:
• Axis computer 2/connector card
• Communication cable (MS2)
• Serial measurement board
• Resolver connection cable

40 504071-01_en.fm
 Control Cabinet
Positioner interface

Axis selector
A contactor that connects the drive unit voltage to the motor is used to activate the
manipulator’s axle.
The contactor is operated using a 24V DC amplifier block, which is controlled by a
digital output from the control system. The control voltage for the contact coil is
230V AC.

Activation signals
Activation/deactivation of the manipulator’s axle can be performed from the
control program or by using the function button under the Jogging menu on the
programming unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.

Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches actuate individual digital inputs in the control system.
Respective inputs are set "high" when the station changer unit is at an end position.

Connecting the manipulator

The motor and resolver signals are gathered in a common output XS101 on the
control cabinet and the manipulator is connected to this output.

Safety
Due to reasons of safety the station changer cannot be set in the operating mode
“MAN FS”. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the personal safety equipment.

504071-01_en.fm 41
Control Cabinet
Positioner interface

3.10 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

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IRBP C/C Index IRBP C/C Index

15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F
18 500 861-881 Säkerh. relä kompl. Safety relay compl.
23 505 966-880 Seriemätkort, kompl. Serial measurement SMB
board, compl.

23.1 505 966-001 Seriemätkort Serial measurement

board
23.5 505 966-003 Batterienhet Battery unit
29 500 157-001 Skärmklämma Clamp 6-16 mm
31 502 152-880 Plåt, kompl. Plate, compl.

39 505 370-880 Kontaktor-modul, Contactor kit, interchange

stn.växel
41 504 153-880 Kabelstam Cable harness IRBP C
42 502 341-881 Kabel Cable W 217
43 502 511-880 Kabel Cable W 230

44 502 517-880 Kabel Cable W 231

45 501 112-001 Digitalt I/O-kort Digital I/O board
46 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
47 500 958-001 Insticksbrygga Address key 7-pol

42 504071-01_en.fm
 Control Cabinet
Positioner interface

18 39

43
23
41

45
42
31

29

46
47

44
15
16
504071C01-1

504071-01_en.fm 43
Control Cabinet
Positioner interface

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QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
505 370-880 Kontaktormodul, Contactor kit, inter-
stationsväxel change

11 193 751-055 Kontaktor Contactor

12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxiliary contact block
27 193 715-707 Modulhållare Module holder 12p

28 193 715-708 Modulhållare Module holder 12p

41 505 367-880 Kabelstam Cable harness
43 502 505-880 Kabel Cable W221-223

44 504071-01_en.fm
 Control Cabinet
Positioner interface

11
27 12
43 28 13

41
505370A01

504071-01_en.fm 45
Control Cabinet
Positioner interface

46 504071-01_en.fm
 Control Cabinet
Positioner interface

3.11 Positioner interface type IRBP L/T

Between the control system and the included positioner there is a modular based
interface fitted to the left of the top cabinet’s rear panel.

6
1

7
8
2
9

10
4

11

5
504072D01-2

1 Connection X6 (not used)

2 Connection X5 Motor Manipulator

3 Resolver connections

4 Digital I/O card

5 Signal connection

6 Motor contactors

7 Brake relay

8 Adapter X4

9 Connection TB2 safety signals

10 Communication cable (MS2) connection

11 Serial measurement board

504072-01_en.fm 47
Control Cabinet
Positioner interface

1
504072a01-3

1 Rectifier with drive unit DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC4
• Drive unit U (included in the rectifier module)
• Cables and connectors for connecting the motors
A thermal contact for temperature monitoring is fitted to the manipulator's motors
to provide protection against overheating. These signals are connected to the
control system's PTC-loop.

Measurement system
For these positioners the measurement system consists of:
• Axis computer 2/connector card
• Communication cable (MS2)
• Serial measurement board
• Cables for connecting resolvers

48 504072-01_en.fm
 Control Cabinet
Positioner interface

Axis selector
A contactor that connects the drive unit voltage to the motor is used to activate
respective manipulators’ axes. The contactor is operated using a 24V DC amplifier
block, which is controlled by a digital output from the control system. The control
voltage for the contact coil is 230V AC.

Activating/deactivating
Activation/deactivation of the manipulator’s axle can be performed from the
control program or by using the function button under the Jogging menu on the
programming unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.

Connecting the manipulator

The motor and resolver signals for respective manipulators are gathered in a
common output on the control cabinet and the manipulator is connected to this
output. The manipulator for station 1 is connected to output XS101 and the
manipulator for station 2 is connected to output XS102.

Safety
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The function of the
contactors is supervised by the safety equipment.

Options
IRBP 5000L
As an option there is a possibility to receive the axis selector with the cabling,
dimensioned for the large “motor currents” that are demanded, in order to run this
type of positioner.

3.12 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

504072-01_en.fm 49
Control Cabinet
Positioner interface

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
504 072-880 Lägeställargränssnitt, Positioner InterFace, M2001
IRBP L/T IRBP L/T

11 504 080-880 Gem. detaljer. 2 aktiver- Common parts, 2 activa-

ingsenheter tion unit
15 193 715-110 Sockel Housing 64-pol
16 193 715-607 Ram Frame 6-mod A-F
19 502 514-880 Kabel Cable W 232

26 502 780-002 Trefas kontaktorbygel Three phase contactor

jumper
29 504 739-880 Byglingsdon Jumper If only 1 posi-
tioner
39 505 371-880 Anslutningsdon, Combi- Connector, CombiCon 12-pol.
Con

50 504072-01_en.fm
 Control Cabinet
Positioner interface

39
26

11

19
15
16
504072D01-1

29

504072-01_en.fm 51
Control Cabinet
Positioner interface

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
OPTION OPTION
504 748-880 Pos IF, IRBP 5000 L Positioner InterFace, M2001
IRBP 5000 L

11 502 341-890 Kabel Cable W217

12 502 505-881 Kabel Cable t W224-225

52 504072-01_en.fm
 Control Cabinet
Positioner interface

11
12
504748B01

504072-01_en.fm 53
Control Cabinet
Positioner interface

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QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
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OPTION OPTION
504 742-880 Åkbana RTT 1400/2400 Travel track RTT 1400/ M2001
+ L/T 2400 + L/T

12 501 111-011 Drivdon Drive unit 2-axes G/U

13 502 338-880 Kabel Cable W215-216
14 502 344-001 Kabel DS (drive system) Cable DS (drive system)
15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F

24 193 715-152 Kåpa Hood
25 193 715-151 Delad kåpa Shared hood
39 489 947-443 Anslutningsdon, Combi- Connector, CombiCon 4-pol
Con

41 504 159-880 Kabelstam Cable harness

42 502 508-880 Kabel Cable W233

54 504072-01_en.fm
 Control Cabinet
Positioner interface

41

42

14
12 13
15
16
24
25
504742C01

39

504072-01_en.fm 55
Control Cabinet
Positioner interface

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
504 080-880 Gem. detaljer, 2 aktiver- Common parts, 2 activa- M2001
ingsenheter tion unit
11 193 751-055 Kontaktor Contactor
12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxilliary contact block

15 500 861-881 Säkerh. relä kompl. 2 växl Safety relay compl.

2 change over contact
16 501 112-001 Digitalt I/O-kort Digital I/O board
17 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
18 500 958-001 Insticksbrygga Address key 7-pol

20 505 966-880 Seriemätkort, kompl. Serial measurement SMB

board, compl.
20.1 505 966-001 Seriemätkort Serial measurement
board
20.5 505 966-003 Batterienhet Battery unit
26 500 157-001 Skärmklämma Clamp 6-16 mm

27 193 715-707 Modulhållare Module bracket

28 193 715-708 Modulhållare Module bracket
31 502 152-880 Plåt kompl. Plate compl.
41 504 150-880 Kabelstam, 2 [Link] Cable harness, 2 [Link]

42 502 505-880 Kabel Cable W221-223

44 502 341-881 Kabel Cable W217
45 502 511-880 Kabel Cable W230
46 502 517-880 Kabel Cable W231

56 504072-01_en.fm
 Control Cabinet
Positioner interface

11
27 12
42 28 13 15

26
20

16

17
18
46
504080D01

45

44 41

504072-01_en.fm 57
Control Cabinet
Positioner interface

58 504072-01_en.fm
 Control Cabinet
Manipulator interface

3.13 Positioner interface types IRBP R/K/E/F

Between the control system and the included positioner there is a modular based
interface fitted to the left of the top cabinet’s rear panel.
1
7
2
8
9

10

5 11

12
6
504073C01-2

1 Connection X5 Motor Positioner

2 Connection X7 Motor Positioner

3 Connection X6 Motor Positioner

4 Resolver connection

5 Digital I/O card

6 Signal connection

7 Motor contactors

8 Brake relay

9 Connection X4

10 Connection TB2 safety signals

11 Communication cable (MS2) connection

12 Serial measurement board

504073-01_en.fm 59
Control Cabinet
Manipulator interface

2
504073a01-3

1 Drive unit G/U

2 Communication cable (DS2) connection

3 Rectifier with drive unit DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC4
• Drive unit U (included in the rectifier module)
• Drive unit G/U
• Cables and connectors for connecting the motors
A thermal contact for temperature monitoring is fitted to the positioners' motors to
provide protection against overheating. These signals are connected to the control
system's PTC-loop.

Measurement system
For this positioner the measurement system consists of:
• Axis computer 2/connector card
• Communication cable (MS2)
• Serial measurement board
• Resolver connection cables

60 504073-01_en.fm
 Control Cabinet
Manipulator interface

Axis selector
A connector is used to activate one of the positioners’ work stations, this is
connected to the drive unit voltage to the motor in question.
The contactor is operated using a 24V DC amplifier block, which is controlled by a
digital output from the control system. The control voltage for the contact coil is
230V AC.
As standard only one axis can be active at any one time.

Activating/deactivating
Activating/deactivating of the positioner’s work stations can be performed from:
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactor for the axis in question is operated via a digital output on activation.
An acknowledgement signal is obtained and a brake release relay with a digital
output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.

Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches set individual digital inputs in the control system.
Respective inputs are set "high" when the station changer unit is at an end position.

Connecting the positioner

Motor and resolver signals for the positioner are separated into two outputs on the
control cabinet, and the positioner is connected to these.
- The motors are connected to the output XS101 and
- the resolvers are connected to the output XS102.

Safety
Due to reasons of safety the station changer cannot be set in the operating mode
“MAN FS”. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the safety equipment.

504073-01_en.fm 61
Control Cabinet
Manipulator interface

3.14 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU

504 073-880 Lägeställargränssnitt, Positioner InterFace, M2001

IRBP R/K/E/F IRBP R/K/E/F

11 504 080-880 Gem. detaljer, 2 aktiver- Common details, 2 activa-

ingsenheter tion unit
13 501 111-011 Drivdon Drive unit 2-axes
14 502 344-001 Kabel DS (Drivsystem) Kabel DS (Drive system)
15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F

39 505 370-880 Kontaktormodul, stations- Contactor kit, interchange
växel
41 504 162-880 Kabelstam Cable harness
42 502 338-880 Kabel Cable W215-216

62 504073-01_en.fm
 Control Cabinet
Manipulator interface

39

42
41

11

14
13
15
16
504073C01-1

504073-01_en.fm 63
Control Cabinet
Manipulator interface

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504 080-880 Gem. detaljer, 2 aktiver- Common parts, 2 activa- M2001
ingsenheter tion unit
11 193 751-055 Kontaktor Contactor
12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxilliary contact block

15 500 861-881 Säkerh. relä kompl. 2 växl Safety relay compl.

2 change over contact
16 501 112-001 Digitalt I/O-kort Digital I/O board
17 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
18 500 958-001 Insticksbrygga Address key 7-pol

20 505 966-880 Seriemätkort, kompl. Serial measurement SMB

board, compl.
20.1 505 966-001 Seriemätkort Serial measurement
board
20.5 505 966-003 Batterienhet Battery unit
26 500 157-001 Skärmklämma Clamp 6-16 mm

27 193 715-707 Modulhållare Module bracket

28 193 715-708 Modulhållare Module bracket
31 502 152-880 Plåt kompl. Plate compl.
41 504 150-880 Kabelstam, 2 [Link] Cable harness, 2 [Link]

42 502 505-880 Kabel Cable W221-223

44 502 341-881 Kabel Cable W217
45 502 511-880 Kabel Cable W230
46 502 517-880 Kabel Cable W231

64 504073-01_en.fm
 Control Cabinet
Manipulator interface

11
27 12
42 28 13 15

26
20

16

17
18
46
504080D01

45

44 41

504073-01_en.fm 65
Control Cabinet
Manipulator interface

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505 370-880 Kontaktormodul, Contactor kit, inter-
stationsväxel change

11 193 751-055 Kontaktor Contactor

12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxiliary contact block
27 193 715-707 Modulhållare Module holder 12p

28 193 715-708 Modulhållare Module holder 12p

41 505 367-880 Kabelstam Cable harness
43 502 505-880 Kabel Cable W221-223

66 504073-01_en.fm
 Control Cabinet
Manipulator interface

11
27 12
43 28 13

41
505370A01

504073-01_en.fm 67
Control Cabinet
Manipulator interface

68 504073-01_en.fm
 Control Cabinet
Positioner interface

3.15 Positioner interface types IRBP B/D

Between the control system and the included positioner there is a modular based
interface fitted to the left of the top cabinet’s rear panel.

1
2 7
8

10

3 11

12
6
504074B01-2

1 Connection X7 Motor Positioner

2 Connection X6 Motor Positioner

3 Connection X5 Motor Positioner

4 Resolver connection

5 Digital I/O card

6 Signal connection

7 Motor contactors

8 Brake relay

9 Connection X4

10 Connection TB2 safety signals

11 Communication cable (MS2) connection

12 Serial measurement board

504074-01_en.fm 69
Control Cabinet
Positioner interface

2
504073a01-3

1 Drive unit G/U

2 Communication cable (DS2) connection

3 Rectifier with drive unit DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC4
• Drive unit U (included in the rectifier module)
• Drive unit G/U
• Cables and connectors for connecting the motors
A thermal contact for temperature monitoring is fitted to the positioners' motors to
provide protection against overheating. These signals are connected to the control
system's PTC-loop.

Measurement system
For this positioner the measurement system consists of:
• Axis computer 2/connector card
• Communication cable (MS2)
• Serial measurement board
• Resolver connection cables

70 504074-01_en.fm
 Control Cabinet
Positioner interface

Axis selector
Contactors are used to activate one of the positioners’ work stations, these are
connected to the drive unit voltage to the motors in question.
The contactors are operated using a 24V DC amplifier block, which is controlled
by a digital output from the control system. The control voltage for the contact
coils is 230V AC.
As standard only one axis can be active at any one time.

Activating/deactivating
Activating/deactivating of the positioner’s work stations can be performed from:
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactors for the mechanical unit in question are operated via a digital output
on activation. An acknowledgement signal is obtained and a brake release relay
with a digital output is then activated.
When deactivating, the motor is stopped before the contactor cuts the drive unit
voltage.

Station indication
In order for the correct production program to be initiated the station changer unit
is equipped with limit switches, that indicate which station is in the working mode
for the robot. The switches set individual digital inputs in the control system.
Respective inputs are set “high” when the station changer unit is at an end position.

Connecting the positioner

Motor and resolver signals for the positioner are separated into two outputs on the
control cabinet, and the positioner is connected to these.
- The motors are connected to the output XS101 and
- the resolvers are connected to the output XS102.

Safety
Due to reasons of safety the station changer cannot be set in the operating mode
“MAN FS”. This interlock is integrated into the interface for operator
communication and safety equipment.
Note! If, for some reason, this interface is omitted it is incumbent on the user
to ensure this interlock is maintained.
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axis. The operation of the
contactors is monitored by the safety equipment.

504074-01_en.fm 71
Control Cabinet
Positioner interface

3.16 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU

504 074-880 Lägeställargränssnitt, Positioner InterFace, M2001

IRBP B/D IRBP B/D

11 504 080-880 Gem. detaljer, 2 aktiver- Common details, 2 activa-

ingsenheter tion unit
13 501 111-011 Drivdon Drive unit 2-axes
14 502 344-001 Kabel DS (Drivsystem) Kabel DS (Drive system)
15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F

19 502 514-880 Kabel Cable W232
26 502 780-002 Trefas kontaktorbygel Three phase contactor
jumper
39 505 370-880 Kontaktormodul, stations- Contactor kit, interchange
växel

40 193 715-709 Modulinsats Module element 12-pol

41 504 156-880 Kabelstam, 2 kontaktorer Cable harness, 2 contac-
tors
42 502 338-880 Kabel Cable W215-216
43 502 505-881 Kabel Cable W224-225

72 504074-01_en.fm
 Control Cabinet
Positioner interface

39
26

42
41

43

11

19

14
13
15
16
504074B01-1

40

504074-01_en.fm 73
Control Cabinet
Positioner interface

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QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
504 080-880 Gem. detaljer, 2 aktiver- Common parts, 2 activa- M2001
ingsenheter tion unit
11 193 751-055 Kontaktor Contactor
12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxilliary contact block

15 500 861-881 Säkerh. relä kompl. 2 växl Safety relay compl.

2 change over contact
16 501 112-001 Digitalt I/O-kort Digital I/O board
17 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
18 500 958-001 Insticksbrygga Address key 7-pol

20 505 966-880 Seriemätkort, kompl. Serial measurement SMB

board, compl.
20.1 505 966-001 Seriemätkort Serial measurement
board
20.5 505 966-003 Batterienhet Battery unit
26 500 157-001 Skärmklämma Clamp 6-16 mm

27 193 715-707 Modulhållare Module bracket

28 193 715-708 Modulhållare Module bracket
31 502 152-880 Plåt kompl. Plate compl.
41 504 150-880 Kabelstam, 2 [Link] Cable harness, 2 [Link]

42 502 505-880 Kabel Cable W221-223

44 502 341-881 Kabel Cable W217
45 502 511-880 Kabel Cable W230
46 502 517-880 Kabel Cable W231

74 504074-01_en.fm
 Control Cabinet
Positioner interface

11
27 12
42 28 13 15

26
20

16

17
18
46
504080D01

45

44 41

504074-01_en.fm 75
Control Cabinet
Positioner interface

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QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
505 370-880 Kontaktormodul, Contactor kit, inter-
stationsväxel change

11 193 751-055 Kontaktor Contactor

12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxiliary contact block
27 193 715-707 Modulhållare Module holder 12p

28 193 715-708 Modulhållare Module holder 12p

41 505 367-880 Kabelstam Cable harness
43 502 505-880 Kabel Cable W221-223

76 504074-01_en.fm
 Control Cabinet
Positioner interface

11
27 12
43 28 13

41
505370A01

504074-01_en.fm 77
Control Cabinet
Positioner interface

78 504074-01_en.fm
 Control Cabinet
Positioner interface

3.17 Positioner interface types IRBP A

Between the control system and the included positioner there is a modular based
interface fitted to the left of the top cabinet’s rear panel.

1
2 7

8
9
3
10

11
5

12
6
504075D01-2

1 Connection X6 Motor Manipulator

2 Connection X5 Motor Manipulator (arm)

3 Connection X7 (not used)

4 Resolver connections

5 Digital I/O card

6 Signal connection

7 Motor contactors

8 Brake relay

9 Adapter X4

10 Connection TB2 safety signals

11 Communication cable (MS2) connection

12 Serial measurement board

504075-01_en.fm 79
Control Cabinet
Positioner interface

3
504075a01-3

2
1

1 Drive unit G/U

2 Communication cable (DS2) connection

3 Rectifier with drive unit DC 4/U

Drive system
For this positioner the drive system consists of:
• Axis computer 2/connector card (DS2)
• Communications cable (DS2)
• Rectifier DC4
• Drive unit U (included in the rectifier module)
• Drive unit G/U
• Cables and connectors for connecting the motors
A thermal contact for temperature monitoring is fitted to the manipulator's motor to
provide protection against overheating. This signal is connected to the control
system's PTC-loop.

Measurement system
For these positioners the measurement system consists of:
• Axis computer 2/connector card (MS2)
• Communication cable (MS2)
• Serial measurement board
• Cables for connecting resolvers

80 504075-01_en.fm
 Control Cabinet
Positioner interface

Axis selector
Two contactors that connect the drive unit voltage to the motors are used to activate
respective manipulators’ axes. Each contactor is operated using a 24V DC
amplifier block, which is controlled by a digital output from the control system.
The control voltage for the contact coil is 230V AC.

Activating/deactivating
Activating/deactivating of the positioner’s respective axes can be performed from
- the control program or
- by using the function key from the jogging menu on the programming
unit.
The contactors for the axes in question are operated via a digital output on
activation. After the ready signal on the acknowledgement input, the brake release
relay is activated by a digital output.
When deactivating, the motors are stopped before the contactors cut the drive unit
voltage.

Connecting the manipulator

The motor and resolver signals for respective manipulators’ motors are gathered in
a common output on the control cabinet and the manipulator is connected to this
output.
- Positioner for station 1 is connected to the output XS101 and
- positioner for station 2 is connected to the output XS102.

Safety
Contactors and auxiliary contact blocks are of an approved redundant type in order
to guarantee assured monitoring of the active motor axes. The function of the
contactors is supervised by the safety equipment.

Working area demarcation

A working area demarcation of the positioner’s arm is made in software. This is
done to protect the cable harness to external motor from accumulated torsional
stress.

3.18 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

504075-01_en.fm 81
Control Cabinet
Positioner interface

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QXPEHU
504 075-880 Lägeställargränssnitt, Positioner InterFace, M2001
IRBP A IRBP A
11 504 080-880 Gem. detaljer, 2 aktiver- Common parts, 2 activa-
ingsenheter tion unit
13 501 111-011 Drivdon Drive unit 2-axes
14 502 344-001 Kabel DS Cable DS Drive system

15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F
19 502 514-880 Kabel Cable W232
23 193 751-055 Kontaktor Contactor

24 193 861-002 Förstärkarblock Amplifier block

25 193 751-105 Hjälpkontaktblock Auxilliary contact block
26 502 780-002 Trefas kontaktorbygel Three phase jumper
27 193 715-707 Modulhållare Module bracket

28 193 715-708 Modulhållare Module bracket

29 504 739-880 Byglingsdon Jumper
39 505 371-880 Anslutningsdon, Combi- Conntector, CombiCon 12-pol.
Con
41 504 156-880 Kabelstam + 2 kontak- Cable harness + 2 contac-
torer tors

42 502 338-880 Kabel Cable W215-216

43 502 505 881 Kabel Cable t W224-225

82 504075-01_en.fm
 Control Cabinet
Positioner interface

23
24
25 26
27
28

42
41

43

11

19

14
13
15
16 504075D01-1

29

504075-01_en.fm 83
Control Cabinet
Positioner interface

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OPTION OPTION
504 746-880 Åkbana RTT, 1400/2400 Travel track RTT, 1400/ M2001
+A 2400 + A

15 193 715-110 Sockel Housing 64-pol

16 193 715-607 Ram Frame 6-mod A-F
24 193 715-152 Kåpa Hood
25 193 715-151 Delad kåpa Shared hood

39 489 947-443 Anslutningsdon, Combi- Connector, CombiCon 4-pol

Con
41 504 159-880 Kabelstam Cable harness
42 502 508-880 Kabel Cable W233

84 504075-01_en.fm
 Control Cabinet
Positioner interface

41

42
24 15
25 16
504746C01

39

504075-01_en.fm 85
Control Cabinet
Positioner interface

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504 080-880 Gem. detaljer, 2 aktiver- Common parts, 2 activa- M2001
ingsenheter tion unit
11 193 751-055 Kontaktor Contactor
12 193 861-002 Förstärkarblock Amplifier block
13 193 751-105 Hjälpkontaktblock Auxilliary contact block

15 500 861-881 Säkerh. relä kompl. 2 växl Safety relay compl.

2 change over contact
16 501 112-001 Digitalt I/O-kort Digital I/O board
17 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7-pol
Con
18 500 958-001 Insticksbrygga Address key 7-pol

20 505 966-880 Seriemätkort, kompl. Serial measurement SMB

board, compl.
20.1 505 966-001 Seriemätkort Serial measurement
board
20.5 505 966-003 Batterienhet Battery unit
26 500 157-001 Skärmklämma Clamp 6-16 mm

27 193 715-707 Modulhållare Module bracket

28 193 715-708 Modulhållare Module bracket
31 502 152-880 Plåt kompl. Plate compl.
41 504 150-880 Kabelstam, 2 [Link] Cable harness, 2 [Link]

42 502 505-880 Kabel Cable W221-223

44 502 341-881 Kabel Cable W217
45 502 511-880 Kabel Cable W230
46 502 517-880 Kabel Cable W231

86 504075-01_en.fm
 Control Cabinet
Positioner interface

11
27 12
42 28 13 15

26
20

16

17
18
46
504080D01

45

44 41

504075-01_en.fm 87
Control Cabinet
Positioner interface

88 504075-01_en.fm
 Control Cabinet
Interface for process equipment

4 Interface for process equipment

4.1 General
Software
Connection of process equipment for arc welding requires a control cabinet
ordered with one of the software options 551/552, ARCWARE/ARCWAREplus.

Welding equipment
For robots IRB140/1400/2400 there is fully prepared welding equipment available
adapted for connection to the system:
Some welding equipment with the wire-feed unit mounted on the robot’s upper arm
utilise the internal cable harness in the robot for connection of signals. In these
cases the robot must be ordered with option 042 "Integrated wire-feed unit cables".

Accessories
The system is prepared for the easy connection of different accessories to the
process equipment such as:
- Mechanical gun cleaner
- Calibration equipment
- Joint location equipment
- Joint tracking equipment

504868-04_en.fm 89
Control Cabinet
Interface for process equipment

4.2 System design

4.2.1 Free-standing welding power source

There is a process control card for communication with the robot’s control system
for control and supervision of the welding power source, wire-feed system and
connected accessories. This is mounted on a module together with other
components for control of the process equipment in the control cabinet.
A process control card with integrated motor regulator is used for welding
equipment from the standard range.
Communication between the process control card and the control system takes
place via a CAN-bus.
This system also makes it possible to control some welding power sources from
other OEM-brands.

Free-standing welding power source

503597A1

Connection of an OEM power source requires you to be fully conversant with the
• operation of the power source,
• how signal transfer should be handled and
• how configuration
of the power source in question should be carried out in the control system.

90 504868-04_en.fm
 Control Cabinet
Interface for process equipment

4.2.2 Welding power source integrated with the control cabinet

Communication with the control system takes place directly via the CAN-bus for
this type of welding power source.
The welding power source is available in two designs, integrated with the control
cabinet or free-standing.
A process control card is used for communication with the robot’s control system
for control and supervision of the wire-feed system and connected accessories.
Arcitec

Welding power source integrated with the control cabinet

504868-04_en.fm 91
Control Cabinet
Interface for process equipment

4.3 Connection
The cable harness to external equipment is connected to the output on the left-hand
side of the top cabinet or to jackable terminals mounted internally by the two-piece
cable gland.

6
1 5
2 4
Output 2

8 3

Figure 17 Connection

1 Wire feed unit motor

2 Wire feed unit - signal

3 Power source

4 Wire feed unit ALU 40 kg

5 TCP tool / Cooling unit

6 Mechanical cleaner

7 Spare / Power source LRC

8 Wire feed unit ALU 40 kg

92 504868-04_en.fm
 Control Cabinet
Interface for process equipment

4.4 No process equipment - Jumper device NO AW

The welding equipment’s interface is replaced by an assembly plate on
installations without welding equipment . All requisite jumper settings, etc for
internal cabling included in the top cabinet are fitted on this.
The assembly plate is fitted on the right-hand side, inside the top cabinet and can
be used as spare space for other customer specific equipment.

4 2 3 1
503270

1 Power supply. A202-X3

2 Jumper device emergency stop. A202-X3

3 Jumper device run chain. A202-X3

4 Termination CAN bus. A202-X3

Power supply
The following voltages are available on the jackable terminal A202-X3:
• 24V DC (24V I/O)
• 115V AC
• 230V AC

503270-01_en.fm 93
Control Cabinet
Interface for process equipment

4.4.1 Control

Interlocks
The following run chain signals are available on the jackable terminal A202-X2:
• Auto stop
• General stop
• External motors on
• External motors on contactor control
The following emergency stop signals are available on the jackable terminal A202-X1:
• External push button
• Emergency stop out
• External limit switches

CAN-bus
The terminated CAN bus channel A202-TB2 can be used, e.g. for the connection
of extra I/O cards.

94 503270-01_en.fm
 Control Cabinet
Interface for process equipment

4.5 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

503270-01_en.fm 95
Control Cabinet
Interface for process equipment

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503 270-880 Processutrustning, Process device,
NO PROC IF NO PROC IF

1 489 947-451 Anslutningsdon, Combi- Connector, CombiCon 12 pol

Con
2 489 947-447 Anslutningsdon, Combi- Connector, CombiCon 8 pol
Con
3 502 796-881 CANBUS-terminering CAN-bus termination
hona female
4 193 817-003 Ändhylsa End sleeve 1.0

5 418 883-006 Kabelkanal Cable trunking

6 489 327-025 Skruv Screw M5X8
7 2126 011-09 Mutter Nut M8
8 2195 013-11 Bricka Washer

9 502 940-087 Enledarkabel Single core

96 503270-01_en.fm
 Control Cabinet
Interface for process equipment

 




 
503270A01

503270-01_en.fm 97
Control Cabinet
Interface for process equipment

98 503270-01_en.fm
 Control Cabinet
Interface for process equipment

4.6 Power source LAW/RPA/OEM

There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.

1 PIB

2 Main contactor

3 Interlock relays

4 Signal connection

5 Transformer
The interface is fitted with internal wiring for connection to the robot control
system.

502784-01_en.fm 99
Control Cabinet
Interface for process equipment

External connection
The cable harness to external equipment is connected to the output on the left-hand
side of the top cabinet or to jackable terminals mounted internally by the two-piece
cable gland.

5
1
4
2
Output 2

1 Wire feed unit motor

2 Wire feed unit - signal

3 Power source

4 TCP tool

5 Mechanical cleaner

Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/42(28)/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 42V AC and
the rectifier part on the process control card with 28V AC.

100 502784-01_en.fm
 Control Cabinet
Interface for process equipment

4.6.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
system’s panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.

502784-01_en.fm 101
Control Cabinet
Interface for process equipment

Figure 18 and Figure 19 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 18 Emergency stop loop

emstopoption

Figure 19 Emergency stop loop with the addition "Extended emergency stop function"

102 502784-01_en.fm
 Control Cabinet
Interface for process equipment

4.6.2 Interlocks

Operating stop loop

Figure 20 below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"

Figure 20 Operating stop loop

Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"

502784-01_en.fm 103
Control Cabinet
Interface for process equipment

CAN bus
&$1EXV&RQQHFWLRQ/$:53$

PIB/node 30 SIB/node 8 I/O/node 21

TB5/M TB6/M X5/M

TB5/F TB6/F X5/F

Termination
unit 
Customer
connection X4/M
CAN1. X6/F X7/F X4/F
2 X6/M X7/M X8/M

CAN1. CAN2
3
I/O/node 10 …... CAN1. A82 Termination
1 X15/M (Connector Board) unit 
X15/F

X5/F X5/M
X5/M X5/F X5/F

- Connection of the process control card is made to the control system’s

CAN-bus channel CAN1.2, output X6 on the contact card A82.
- The connection cable should be fitted with a termination resistance,
120Ω

Process control card

The control card houses the hardware and software for control and regulation of
the arc welding equipment.
501700A01

- See the Product Manual for the welding equipment/S4Cplus.

104 502784-01_en.fm
 Control Cabinet
Interface for process equipment

4.6.3 Connections for external equipment

Welding power source

1 Welding power sources type LAW/RPA are connected to output XS107.

- A detailed account of available signals is given in the separate manual
for the process control card in the section “Process equipment” chapter
PIB.

2 Power sources from other manufacturer's can be connected to this output

under the condition that they comply with the specifications described in
the manual "Welding equipment" in the section "Process equipment"
chapter PIB.

3 If another type/configuration of the output is required, the cable W240 can

be replaced by another internal cable.

4 If the welding power supply is fitted with an emergency stop it can be

connected to the jackable terminal A202-X1.
- See the separate manual in the section “Power Source” for a description
of included welding power sources.

Feed mechanism system

Feed mechanism system types A140E, A314E resp. A324E-L are connected to
outputs XS105 and XS106.
- See the separate manual in the section “Process equipment” chapter PIB
for a description of included feed mechanism systems.

Other accessories

1 The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.

2 Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the left-
hand side, inside the top cabinet.

3 See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.

502784-01_en.fm 105
Control Cabinet
Interface for process equipment

4.7 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

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QXPEHU

502 784-880 Processutrustning Process equipment LAW/RPA

1 502 501-880 [Link]. matarverk 42V Common details wire feed

unit 42V
2 436 829-009 Jordklämma Clamp
3 2126 011-09 Mutter Nut M8
4 2195 013-11 Bricka Washer

5 418 159-020 Täcklock fläns Cover cap flange 8+12 pol

6 418 159-019 Täcklock fläns Cover cap flange 19+23 pol
7 489 327-012 Skruv Screw M3X12
8 2126 011-03 Mutter Nut M3

9 193 715-152 Kåpa Hood

10 193 715-151 Delad kåpa, max 4 kablar Shared hood,max 4
cables
11 193 715-167 Blindpropp Blind plug
12 489 327-019 Skruv Screw M4x12

13 192 230-110 Blindpropp Blind plug D=20

14 503 260-880 Kabel till strömkälla Cable to power source W240
(intern) (internal)

106 502784-01_en.fm
 Control Cabinet
Interface for process equipment

3/4

2 14 1

9/10/11/12

5/7/8/13
502784A01

6/7/8/12

502784-01_en.fm 107
Control Cabinet
Interface for process equipment

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502 501-880 Gem. detaljer till Common details to wire
matarverk 42V feed unit 42V

1 193 751-055 Kontaktor Contactor

2 193 861-002 Förstärkarblock Amplifier block
3 193 751-105 Hjälpkontaktblock Auxilliary contact block
4 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
Change over contact

5 501 700-880 Process interface board Process interface board PIB

6 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7pol
Con
7 500 958-001 Insticksbrygga Address key 7-pol
8 501 714-001 Trafo PIB standard Transformer PIB standard

9 418 883-006 Kabelkanal Cable trunking

10 489 327-025 Skruv Screw M5X8
11 502 777-880 Kabelstam Cable harness
12 503 251-880 Kabel till matarverk, Cable to wire feed unit, W241
internt 1 internal 1

13 503 254-880 Kabel till matarverk, Cable to wire feed unit, W242
internt 2 internal 2
14 503 257-880 Kabel, BullsEye/TC Cable, BullsEye/TC W243

108 502784-01_en.fm
 Control Cabinet
Interface for process equipment

1/2/3
11
6/7

9/10 5

13

12

14
502501A01

502784-01_en.fm 109
Control Cabinet
Interface for process equipment

110 502784-01_en.fm
 Control Cabinet
Interface for process equipment

4.8 MILLER
There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.

1 PIB

2 Main contactor

3 Interlock relays

4 Signal connection

5 Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.

502786-01_en.fm 111
Control Cabinet
Interface for process equipment

- The cable harness to external equipment is connected to the output on

the left-hand side of the top cabinet or to jackable terminals mounted
internally by the two-piece cable gland.

20 19 18

17
1 16
15
20 14

13
2
12
20
11
20 10

9
4
8
3 7
5
Output 2

20

1. Positioner 11. Timer resetting stn 1

2. Conveyor motor/resolver 12. Light barrier 2
3. Operator’s panel 13. Light barrier 1
4. Wire feed unit motor 14. Gate switch
5. Wire feed unit - signal 15. Gate reset
6. Power source 16. Activation unit work area 2/Home Sensor 2
7. Wire cutter 17. Activation unit work area 1/Home Sensor 1
8. TCP tool 18. Limit switch for conveyor
9. Mechanical cleaner 19. Position indicator for conveyor
10. Timer reset stn 2 20. Spare

112 502786-01_en.fm
 Control Cabinet
Interface for process equipment

Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/115/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 115V AC and
the rectifier part on the process control card with 28V AC.

4.8.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
system’s panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.

502786-01_en.fm 113
Control Cabinet
Interface for process equipment

Figure 21 and Figure 22 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 21 Emergency stop loop

emstopoption

Figure 22 Emergency stop loop with the addition "Extended emergency stop function"

114 502786-01_en.fm
 Control Cabinet
Interface for process equipment

4.8.2 Interlocks

Operating stop loop

Figure 23 below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"

Figure 23 Operating stop loop

Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"

502786-01_en.fm 115
Control Cabinet
Interface for process equipment

CAN-bus

&$1EXV&RQQHFWLRQ/$:53$

PIB/node 30 SIB/node 8 I/O/node 21

TB5/M TB6/M X5/M

TB5/F TB6/F X5/F

Termination
unit 
Customer
connection X4/M
CAN1. X6/F X7/F X4/F
2 X6/M X7/M X8/M

CAN1. CAN2
3
I/O/node 10 …... CAN1. A82 Termination
1 X15/M (Connector Board) unit 
X15/F
X5/F X5/M
X5/M X5/F X5/F

Figure 24 CAN-bus

- Connection of the process control card is made to the control system’s

CAN-bus channel CAN1.2, output X6 on the contact card A82.
- The connection cable should be fitted with a termination resistance,
120Ω.

116 502786-01_en.fm
 Control Cabinet
Interface for process equipment

Process control card

The control card houses the hardware and software for control and regulation of
the arc welding equipment.
501700A01

See the Product Manual for the welding equipment/S4Cplus.

4.8.3 Connections for external equipment

Welding power source

1 Welding power sources type Miller are connected to output XS107.

- A detailed account of available signals is given in the separate manual
for the process control card in the section “Process equipment” chapter
PIB.

2 Power sources from other manufacturer's can be connected to this output

under the condition that they comply with the specifications described in
the manual "Welding equipment" in the section "Process equipment"
chapter PIB.

3 If another type/configuration of the output is required, the cable W240 can

be replaced by another internal cable.

4 If the welding power supply is fitted with an emergency stop it can be

connected to the jackable terminal A202-X1.

502786-01_en.fm 117
Control Cabinet
Interface for process equipment

Feed mechanism system

Feed mechanism systems type A140E, A314E and A324E-L are connected to
outputs XS105 and XS106.
- See the separate manual in the section “Process equipment” chapter PIB
for a description of included feed mechanism systems.

Other accessories

1 The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.

2 Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the left-
hand side, inside the top cabinet.

3 See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.

118 502786-01_en.fm
 Control Cabinet
Interface for process equipment

4.9 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

502786-01_en.fm 119
Control Cabinet
Interface for process equipment

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502 786-880 Processutrustning Process equipment MILLER

1 502 503-880 [Link]. matarverk 115V Common details wire feed

unit 115V
2 436 829-009 Jordklämma Clamp
3 2126 011-09 Mutter Nut M8
4 2195 013-11 Bricka Washer

5 418 159-020 Täcklock fläns Cover cap flange 8+12 pol

6 418 159-019 Täcklock fläns Cover cap flange 19+23 pol
7 489 327-012 Skruv Screw M3X12
8 2126 011-03 Mutter Nut M3

9 193 715-152 Kåpa Hood

10 193 715-151 Delad kåpa, max 4 kablar Shared hood, max 4
cables
11 193 715-167 Blindpropp Blind plug
12 489 327-019 Skruv Screw M4X12

13 192 230-110 Blindpropp Blind plug D=20

14 503 260-880 Kabel till strömkälla, intern Cable to power source, W240
internal

120 502786-01_en.fm
 Control Cabinet
Interface for process equipment

5/7/8/12/13 3/4

9/10/11/12 6/7/8/12 14 1
502786

502786-01_en.fm 121
Control Cabinet
Interface for process equipment

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QXPEHU
502 503-880 Gem. detaljer, matarverk Common details, wire
115V feed unit 115V

1 193 751-055 Kontaktor Contactor

2 193 861-002 Förstärkarblock Amplifier block
3 193 751-105 Hjälpkontaktblock Auxilliary contact block
4 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
change over contact

5 501 700-881 Process interface board Process interface board PIB

6 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7pol
Con
7 500 958-001 Insticksbrygga Address key 7-pol
8 501 714-002 Trafo PIB för MILLER Transformer PIB for
MILLER

9 418 883-006 Kabelkanal Cable trunking

10 489 327-025 Skruv Screw M5X8
11 502 777-880 Kabelstam proc Cable harness proc
12 503 251-880 Kabel till matarverk, Cable to wire feed unit, W241
internt 1 internal 1

13 503 254-880 Kabel till matarverk, Cable to wire feed unit, W242
internt 2 internal 2
14 503 257-880 Kabel till Bullseye/TC Cable to Bullseye/TC W243

122 502786-01_en.fm
 Control Cabinet
Interface for process equipment

1/2/3

11
6/7

9/10
5

12 14
13
502503A01

502786-01_en.fm 123
Control Cabinet
Interface for process equipment

124 502786-01_en.fm
 Control Cabinet
Interface for process equipment

4.10 Power source ARCITEC-LRB

There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.

1 PIB

2 Main contactor

3 Interlock relays

4 Signal connection

5 Auxiliary fan, cooling unit

6 Transformer
- The interface is fitted with internal wiring for connection to the robot
control system.

502785-01_en.fm 125
Control Cabinet
Interface for process equipment

- The cable harness to external equipment is connected to the output on

the left-hand side of the top cabinet or to jackable terminals mounted
internally by the two-piece cable gland. Internal cables for control
signals to the welding power source are also connected here.

20

20

20
20

9
4
8
5
Output 2

20

4. Wire feed unit motor

5. Wire feed unit - signal
8. TCP tool
9. Mechanical cleaner
20. Spare

Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/42(28)/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 42V AC and
the rectifier part on the process control card with 28V AC.

126 502785-01_en.fm
 Control Cabinet
Interface for process equipment

4.10.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
system’s panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.

502785-01_en.fm 127
Control Cabinet
Interface for process equipment

Figure 25 and Figure 26 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 25 Emergency stop loop

emstopoption

Figure 26 Emergency stop loop with the addition "Extended emergency stop function"

128 502785-01_en.fm
 Control Cabinet
Interface for process equipment

4.10.2 Interlocks

Operating stop loop

Figure 27 below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"

Figure 27 Operating stop loop

Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"

502785-01_en.fm 129
Control Cabinet
Interface for process equipment

CAN bus

&$1EXV&RQQHFWLRQ/5%

SLRB/eipaw

XP4/M
PIB/node 30 SIB/node 8 I/O/node 21
XS4/F
Termination
unit 
TB5/M Burnd TB6/M X5/M
TB5/F y 12- TB6/F X5/F

X6B/M
X6/F
pol

Customer
connection X4/M
CAN1. X6/F X7/F X4/F
2 X6/M X7/M X8/M

CAN1. CAN2
3
I/O/node 10 …... CAN1. A82 Termination
1 X15/M Connector Board unit 
X15/F
X5/F X5/M
X5/M X5/F X5/F

Figure 28 CAN-bus

- The welding power source is connected to the control system’s CAN-bus

channel CAN1.2, output X6 on contact card A82, using a branch cable.
- The process control card’s connection cable is connected to the same
CAN-bus channel via output X6B on this branch cable.
- The connection cable should be fitted with a termination resistance,
120Ω.

130 502785-01_en.fm
 Control Cabinet
Interface for process equipment

Process control card

The control card houses the hardware and software for control and regulation of
the arc welding equipment.
501700A01

See the Product Manual for the welding equipment/S4Cplus.

4.10.3 Connecting integrated welding power sources

1 The cables for the supply voltage are connected to the control cabinet’s
main power switch.

2 Connections for communication with the control cabinet’s CAN-bus are

made to output X6 on contact card A82

3 Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.

4 See the separate manual in the section “Power Source” for a description of
included welding power sources.

4.10.4 Connections for external equipment

Feed mechanism system

Feed mechanism system types A140E, A314E resp. A324E-L are connected to
outputs XS105 and XS106.
- See the separate manual in the section “Process equipment” chapter PIB
for a description of included feed mechanism systems.

502785-01_en.fm 131
Control Cabinet
Interface for process equipment

Other accessories

1 The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.

2 Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the left-
hand side, inside the top cabinet
- See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.

3 A cooling unit is required if a water cooled gun is included.

- The cable from the cooling unit is inserted through the two-piece cover
and is connected to the jackable terminal X202 located on the left-hand
side, inside the top cabinet.
- See the separate manual under section "Cooling unit" for a description of
the cooling unit.

132 502785-01_en.fm
 Control Cabinet
Interface for process equipment

4.11 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

502785-01_en.fm 133
Control Cabinet
Interface for process equipment

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
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QXPEHU
502 785-880 Processutrustning Process equipment LRB

1 502 501-880 Gem. detaljer för Common details wire feed

matarverk 42V unit 42V
2 436 829-009 Jordklämma Clamp
3 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
change over contact
4 2126 011-09 Mutter Nut M8

5 2195 013-11 Bricka Washer

6 418 159-019 Täcklock fläns Cover cap flange 19+23 pol
7 489 327-012 Skruv Screw M3X12
8 2126 011-03 Mutter Nut M3

9 193 715-152 Kåpa Hood

10 193 715-151 Delad kåpa, max 4 kablar Shared hood,max 4
cables
11 193 715-167 Blindpropp Blind plug
12 489 327-019 Skruv Screw M4X12

13 193 715-159 Kabel tätning Cable gland D=9-10mm

14 502 797 880 Kabelstam LRB (ARCI- Cable harness LRB
TEC) (ARCITEC)

134 502785-01_en.fm
 Control Cabinet
Interface for process equipment

4/5 3

2 14 1
9/10/11/12/13

6/7/8/12
502785A01

502785-01_en.fm 135
Control Cabinet
Interface for process equipment

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
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QXPEHU
502 501-880 Gem. detaljer till Common details to wire
matarverk 42V feed unit 42V

1 193 751-055 Kontaktor Contactor

2 193 861-002 Förstärkarblock Amplifier block
3 193 751-105 Hjälpkontaktblock Auxilliary contact block
4 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
Change over contact

5 501 700-880 Process interface board Process interface board PIB

6 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7pol
Con
7 500 958-001 Insticksbrygga Address key 7-pol
8 501 714-001 Trafo PIB standard Transformer PIB standard

9 418 883-006 Kabelkanal Cable trunking

10 489 327-025 Skruv Screw M5X8
11 502 777-880 Kabelstam Cable harness
12 503 251-880 Kabel till matarverk, Cable to wire feed unit, W241
internt 1 internal 1

13 503 254-880 Kabel till matarverk, Cable to wire feed unit, W242
internt 2 internal 2
14 503 257-880 Kabel, BullsEye/TC Cable, BullsEye/TC W243

136 502785-01_en.fm
 Control Cabinet
Interface for process equipment

1/2/3
11
6/7

9/10 5

13

12

14
502501A01

502785-01_en.fm 137
Control Cabinet
Interface for process equipment

138 502785-01_en.fm
 Control Cabinet
Interface for process equipment

4.12 Power source ARCITEC-LRC

There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.

1 PIB

2 Main contactor

3 Interlock relays

4 Signal connection

5 Auxiliary fan, cooling unit

6 Transformer

- The interface is fitted with internal wiring for connection to the robot
control system.

503360-01_en.fm 139
Control Cabinet
Interface for process equipment

- The cable harness to external equipment is connected to the output on

the left-hand side of the top cabinet or to jackable terminals mounted
internally by the two-piece cable gland. External cables for control
signals to the welding power source are also connected here.

20 19 18

17
1 16
15
20 14

13
2
12
20
11
20 10

9
4
8
3 7
5
Output 2

20

1. Positioner 11. Timer resetting stn 1

2. Conveyor motor/resolver 12. Light barrier 2
3. Operator’s panel 13. Light barrier 1
4. Wire feed unit motor 14. Gate switch
5. Wire feed unit - signal 15. Gate reset
6. Power source 16. Activation unit work area 2/Home Sensor 2
7. Wire cutter 17. Activation unit work area 1/Home Sensor 1
8. TCP tool 18. Limit switch for conveyor
9. Mechanical cleaner 19. Position indicator for conveyor
10. Timer reset stn 2 20. Spare

140 503360-01_en.fm
 Control Cabinet
Interface for process equipment

Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/42(28)/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 42V AC and
the rectifier part on the process control card with 28V AC.

4.12.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
system’s panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.

503360-01_en.fm 141
Control Cabinet
Interface for process equipment

Figure 29 and Figure 30 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 29 Emergency stop loop

emstopoption

Figure 30 Emergency stop loop with the addition "Extended emergency stop function"

142 503360-01_en.fm
 Control Cabinet
Interface for process equipment

4.12.2 Interlocks

Operating stop loop

Figure 31 below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"

Figure 31 Operating stop loop

Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"

503360-01_en.fm 143
Control Cabinet
Interface for process equipment

CAN bus

&$1EXV&RQQHFWLRQ/5&

SLRC/eipaw

XP4/M
XS4/F
Burnd
Termination y 12-
unit  pol

XP107/M
XS107/F

PIB/node 30 SIB/node 8 I/O/node 21

Burnd
y
TB5/M TB6/M X5/M
TB5/F X5/F

X6B/M
TB6/F

X6/F
Customer
connection X4/M
CAN1. X6/F X7/F X4/F
2 X6/M X7/M X8/M

CAN1. CAN2
3
I/O/node 10 …... CAN1. A82 Termination
1 X15/M Connector Board unit 
X15/F
X5/F X5/M
X5/M X5/F X5/F

Figure 32 CAN-bus

- The CAN-bus cable to the welding power source is connected to output

X107. This output is internally connected to the control system’s CAN-
bus channel CAN1.2, output X6 on contact card A82, using a branch
cable.
- The process control card’s connection cable is connected to the same
CAN-bus channel via output X6B on this branch cable.
- The connection cable should be fitted with a termination resistance,
120Ω.

144 503360-01_en.fm
 Control Cabinet
Interface for process equipment

Process control card

The control card houses the hardware and software for control and regulation of
the arc welding equipment.
501700A01

See the Product Manual for the welding equipment/S4Cplus.

4.12.3 Connecting integrated welding power sources

1 Connections for communication with the control cabinet’s CAN-bus are

made to output X107 on the control cabinet.

2 Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.

3 See the separate manual in the section “Power Source” for a description of
included welding power sources.

4.12.4 Connections for external equipment

Feed mechanism system

Feed mechanism system types A140E, A314E resp. A324E-L are connected to
outputs XS105 and XS106.
- See the separate manual in the section “Process equipment” chapter PIB
for a description of included feed mechanism systems.

503360-01_en.fm 145
Control Cabinet
Interface for process equipment

Other accessories

1 The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.

2 Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the left-
hand side, inside the top cabinet

3 See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.
- A cooling unit is required if a water cooled gun is included.
- The cable from the cooling unit is inserted through the two-piece cover
and is connected to the jackable terminal X202 located on the left-hand
side, inside the top cabinet
- See the separate manual under section "Cooling unit" for a description of
the cooling unit.

146 503360-01_en.fm
 Control Cabinet
Interface for process equipment

4.13 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

503360-01_en.fm 147
Control Cabinet
Interface for process equipment

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
503 360-880 Processutrustning Process equipment LRC

1 502 501-880 [Link]. matarverk 42V Common details wire feed

unit 42V
2 436 829-009 Jordklämma Clamp
3 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
change over contact
4 2126 011-09 Mutter Nut M8

5 2195 013-11 Bricka Washer

6 418 159-020 Täcklock fläns Cover cap flange 8+12 pol
7 418 159-019 Täcklock fläns Cover cap flange 19+23 pol
8 489 327-012 Skruv Screw M3X12

9 2126 011-03 Mutter Nut M3

10 193 715-152 Kåpa Hood
11 193 715-151 Delad kåpa, max 4 kablar Shared hood, max 4
cables
12 193 715-167 Blindpropp Blind plug

13 489 327-019 Skruv Screw M4X12

14 192 230-110 Blindpropp Blind plug D=20
15 193 715-159 Kabel tätning Cable gland D=9-10mm
16 502 797 880 Kabelstam LRB (ARCI- Cable harness LRB
TEC II) (ARCITEC)

17 503 078-881 [Link] CANBUS W246 [Link] CAN-bus W246

LRC LRC

148 503360-01_en.fm
 Control Cabinet
Interface for process equipment

4/5 3

17

10/11/12/13/15 16 1

6/8/9/13/14

7/8/9/13
503360A01

503360-01_en.fm 149
Control Cabinet
Interface for process equipment

3RVLWLRQV
QXPPHU $QWDO %HVWlOOQLQJVQXPPHU $QPlUNQLQJDU
%HQlPQLQJ 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJQXPEHU 5HPDUNV
QXPEHU
502 501-880 Gem. detaljer till Common details to wire
matarverk 42V feed unit 42V

1 193 751-055 Kontaktor Contactor

2 193 861-002 Förstärkarblock Amplifier block
3 193 751-105 Hjälpkontaktblock Auxilliary contact block
4 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
Change over contact

5 501 700-880 Process interface board Process interface board PIB

6 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7pol
Con
7 500 958-001 Insticksbrygga Address key 7-pol
8 501 714-001 Trafo PIB standard Transformer PIB standard

9 418 883-006 Kabelkanal Cable trunking

10 489 327-025 Skruv Screw M5X8
11 502 777-880 Kabelstam Cable harness
12 503 251-880 Kabel till matarverk, Cable to wire feed unit, W241
internt 1 internal 1

13 503 254-880 Kabel till matarverk, Cable to wire feed unit, W242
internt 2 internal 2
14 503 257-880 Kabel, BullsEye/TC Cable, BullsEye/TC W243

150 503360-01_en.fm
 Control Cabinet
Interface for process equipment

1/2/3
11
6/7

9/10 5

13

12

14
502501A01

503360-01_en.fm 151
Control Cabinet
Interface for process equipment

152 503360-01_en.fm
 Control cabinet
Interface for process equipment

4.14 Power source ARCITEC-LRB ALUMINIUM

There is a modular based interface between the control system and component
welding equipment fitted on the right-hand side, inside the top cabinet.

1 PIB

2 Main contactor

3 Interlock relays

4 Signal connection

5 Auxiliary fan, cooling unit

6 Transformer

- The interface is fitted with internal wiring for connection to the robot
control system.

502891-01_en.fm 153
Control cabinet
Interface for process equipment

- The cable harness to external equipment is connected to the output on

the left-hand side of the top cabinet or to jackable terminals mounted
internally by the two-piece cable gland. Internal cables for control
signals to the welding power source are also connected here.

20 19 18

17
1 16
15
20 14

13
2
12
20
11
20 10

9
4
8
3 7
5
Output 2

20

1. Positioner 11. Timer resetting stn 1

2. Conveyor motor/resolver 12. Light barrier 2
3. Operator’s panel 13. Light barrier 1
4. Wire feed unit motor 14. Gate switch
5. Wire feed unit - signal 15. Gate reset
6. Power source 16. Activation unit work area 2/Home Sensor 2
7. Wire cutter 17. Activation unit work area 1/Home Sensor 1
8. TCP tool 18. Limit switch for conveyor
9. Mechanical cleaner 19. Position indicator for conveyor
10. Timer reset stn 2 20. Spare

154 502891-01_en.fm
 Control cabinet
Interface for process equipment

Power supply
The voltage supply consists of a ring core transformer with double secondary
windings 230/(42) 28/28V AC (see technical specification for PIB).
This feeds the motor regulator part on the process control card with 115V AC and
the rectifier part on the process control card with 28V AC.

4.14.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
There is a possibility of connecting this in series with the other push buttons in the
system if the process equipment is fitted with emergency stop push button.
The equipment is normally interlocked via the emergency stop relay on the control
system’s panel card A81.
The "Extended emergency stop function" option gives the possibility of
supplementing the equipment with components. Optional redundant auxiliary
relays can then be easily connected for this purpose.

502891-01_en.fm 155
Control cabinet
Interface for process equipment

Figure 33 and Figure 34 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 33 Emergency stop loop

emstopoption

Figure 34 Emergency stop loop with the addition "Extended emergency stop function"

156 502891-01_en.fm
 Control cabinet
Interface for process equipment

4.14.2 Interlocks

Operating stop loop

Figure 35 below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"

Figure 35 Operating stop loop

Two channel break up of the operating stop loop on the process control card.
In order to run the wire feed motor and welding equipment in all operating modes
requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
In order to run the wire feed motor at a limited speed requires:
- the emergency stop loop to be intact
- operating mode "MAN" and the system set to "MOTORS OFF"

502891-01_en.fm 157
Control cabinet
Interface for process equipment

CAN-bus

&$1EXV&RQQHFWLRQ/5%

SLRB/eipaw

XP4/M
PIB/node 30 SIB/node 8 I/O/node 21
XS4/F
Termination
unit 
TB5/M Burnd TB6/M X5/M
TB5/F y 12- TB6/F X5/F

X6B/M
X6/F
pol

Customer
connection X4/M
CAN1. X6/F X7/F X4/F
2 X6/M X7/M X8/M

CAN1. CAN2
3
I/O/node 10 …... CAN1. A82 Termination
1 X15/M Connector Board unit 
X15/F
X5/F X5/M
X5/M X5/F X5/F

Figure 36 CAN-bus

- The welding power source is connected to the control system’s CAN-bus

channel CAN1.2, output X6 on contact card A82, using a branch cable.
- The process control card’s connection cable is connected to the same
CAN-bus channel via output X6B on this branch cable.
- The connection cable should be fitted with a termination resistance,
120Ω.

158 502891-01_en.fm
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Interface for process equipment

Process control card

The control card houses the hardware and software for control and regulation of
the arc welding equipment.
501700A01

See the Product Manual for the welding equipment/S4Cplus.

4.14.3 Connecting integrated welding power sources

1 The cables for the supply voltage are connected to the control cabinet’s
main power switch.

2 Connections for communication with the control cabinet’s CAN-bus are

made to output X6 on contact card A82

3 Cables for control signals to welding power sources type LRB are
connected to the jackable terminal X202.

4 See the separate manual in the section “Power Source” for a description of
included welding power sources.

4.14.4 Connections for external equipment

Feed mechanism system

Feed mechanism system types A314E, A324E-L resp. A314i ALU and A324iL
ALU are connected to outputs XS105 and XS106
- See the separate manual in the section “Process equipment” chapter PIB
for a description of included feed mechanism systems.

502891-01_en.fm 159
Control cabinet
Interface for process equipment

Other accessories

1 The equipment is prepared for the connection of, e.g. mechanical cleaners
and calibration tools.

2 Cabling from the welding gun equipment is inserted through the two-piece
cover and is connected to the jackable terminal X108 located on the left-
hand side, inside the top cabinet

3 See the separate manual under section "Cooling unit" and "Gun service
unit" for a description of component products.

4 A cooling unit is required if a water cooled gun is included.

- The cable from the cooling unit is inserted through the two-piece cover
and is connected to the jackable terminal X202 located on the left-hand
side, inside the top cabinet
- See the separate manual under section "Cooling unit" for a description of
the cooling unit.

160 502891-01_en.fm
 Control cabinet
Interface for process equipment

4.15 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

502891-01_en.fm 161
Control cabinet
Interface for process equipment

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1 502 501-880 [Link]. matarverk 42V Common details wire feed

unit 42V
2 436 829-009 Jordklämma Clamp
3 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
change over contact
4 2126 011-09 Mutter Nut M8

5 2195 013-11 Bricka Washer

6 418 159-020 Täcklock fläns Cover cap flange 8+12 pol
7 418 159-019 Täcklock fläns Cover cap flange 19+23 pol
8 489 327-012 Skruv Screw M3X12

9 2126 011-03 Mutter Nut M3

10 193 715-152 Kåpa Hood
11 193 715-151 Delad kåpa, max 4 kablar Shared hood, max 4
cables
12 193 715-167 Blindpropp Blind plug

13 489 327-019 Skruv Screw M4X12

14 192 230-110 Blindpropp Blind plug D=20
15 193 715-159 Kabel tätning Cable gland D=9-10mm
16 502 797 880 Kabelstam LRB (ARCI- Cable harness LRB
TEC II) (ARCITEC)

162 502891-01_en.fm
 Control cabinet
Interface for process equipment

45 3

10 11 12 13 15 16 1

6 8 9 13 14

7 8 9 13
502891A01

502891-01_en.fm 163
Control cabinet
Interface for process equipment

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matarverk 42V feed unit 42V

1 193 751-055 Kontaktor Contactor

2 193 861-002 Förstärkarblock Amplifier block
3 193 751-105 Hjälpkontaktblock Auxilliary contact block
4 500 861-881 Sä[Link]ä kompl.2växl Safety relay compl. 2
Change over contact

5 501 700-880 Process interface board Process interface board PIB

6 489 947-244 Anslutningsdon, Combi- Connector, CombiCon 7pol
Con
7 500 958-001 Insticksbrygga Address key 7-pol
8 501 714-001 Trafo PIB standard Transformer PIB standard

9 418 883-006 Kabelkanal Cable trunking

10 489 327-025 Skruv Screw M5X8
11 502 777-880 Kabelstam Cable harness
12 503 251-880 Kabel till matarverk, Cable to wire feed unit, W241
internt 1 internal 1

13 503 254-880 Kabel till matarverk, Cable to wire feed unit, W242
internt 2 internal 2
14 503 257-880 Kabel, BullsEye/TC Cable, BullsEye/TC W243

164 502891-01_en.fm
 Control cabinet
Interface for process equipment

1/2/3
11
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9/10 5

13

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502891-01_en.fm 165
Control cabinet
Interface for process equipment

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X 502 891-880 [Link]. ALUMINIUM 7kg [Link]. ALUMINIUM see earlier page
7kg
1 489 947-445 Anslutningsdon, Combi- Connector, CombiCon 6 pol
Con
2 193 817-004 Ändhylsa End bracket
3 502 940-101 Enledarkabel Single core

4 489 327-012 Skruv Screw M3X12

5 212 601-103 Mutter Nut M3
6 503 087-880 Kabelm internt. OPT:ALU Cable, internal. [Link] W247

166 502891-01_en.fm
 Control cabinet
Interface for process equipment

45 23 6
502895A01

502891-01_en.fm 167
Control cabinet
Interface for process equipment

168 502891-01_en.fm
 Control Cabinet
Interface for operator communications and safety

5 Interface for operator communications and safety

5.1 General
There is complete equipment available for operator communications and safety
supervision adapted to the system for station solutions where the layout follows
standard layout principles.
Through the addition of different accessories for this equipment, handling can be
adapted to meet special requirements.

Operator communication
Communication between the operator and the control system takes place via
a panel with push-buttons and status lamps.
Operations and acknowledgements are converted to digital input and output
signals.

5.1.1 Safety functions

Emergency stop loop

All emergency stop buttons included in the station are usually connected to the
control system’s emergency stop loop. If one of these push-buttons is activated
all dangerous machine movement is stopped immediately and the system is set
in "Motors off mode".

Operating stop loop

Connected safety supervision equipment normally works with the control system’s
operating stop loop. If something unpermitted occurs either the general stop or
auto stop is tripped depending on the incident.
This results in dangerous machine movement being stopped immediately and the
system being set in "Motors off mode".
For further information about the design of the safety system refer to the robot’s
"User Guide".
Note! Connected safety functions must not be overridden under any
circumstances. This can result in serious personal injury.
Read the instructions in the System Manual, chapter 1 "Introduction and Safety"
before the station is used.

504868-05_en.fm 169
Control Cabinet
Interface for operator communications and safety

5.1.2 Accessories
The system is prepared for the connection of different accessories in order to
optimise handling as required, these are:
- Operator panel
- Light barriers
- Gate supervision
- Timer resetting
- Home position/transport position indication
- Station indication with the service position
- Activation from extended programming area
- Roller door (FlexArc)
For further information about the safety equipment, refer to the Product Manual for
the "Safety equipment"

170 504868-05_en.fm
 Control Cabinet
Interface for operator communications and safety

5.2 System solutions

Continuous status supervision of safety components, operator communications and
moving machine parts is required in order to prevent personal danger when
entering supervised areas.
This is provided by a circuit card for safety supervision, located in the top cabinet.
The circuit card includes functions to immediately cut the control system’s
operating loop when a course of events occur that can result in personal danger.
Examples of events are:
- hardware failure in safety equipment
- incorrect operation
- carelessness
- machine fault
Safety equipment is designed according to category 4 described in EN 954-1,
doubled and self-supervision.
The equipment can be adapted for optimal handling in each individual case by
connecting different accessories to the circuit board.

5.2.1 Traditional welding robot station

1
4

2
3
6

Figure 37 Traditional welding robot station

1 Robot 6 Supervised area station 2

2 Positioner 7 Supervised programming area
3 Operator panel 8 Barrier
4 Light barriers 9 Service door
5 Supervised area station 1

504868-05_en.fm 171
Control Cabinet
Interface for operator communications and safety

5.2.2 FlexArc
FlexArc is a complete welding robot station built on a base plate including walls.
The total solution gives easy connection and rapid start-up.
FlexArc always incorporates safety with a light barrier or roller door.

1
2

4
504000-7

7
3

Figure 38 FlexArc 250R with light barriers

1 Robot 5 Supervised area

2 Positioner 6 Supervised programming area
3 Operator panel 7 Barrier
4 Light barriers 8 Service door

172 504868-05_en.fm
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Interface for operator communications and safety

5.3 Connections
The cable harness to external equipment is connected to the output on the left-hand
side of the top cabinet or to jackable terminals mounted internally by the two-piece
cable gland.

5.3.1 General

1 8
2 9
3 10
4 11

12
13
5
14
6 15

7
Uttag2

Figure 39 General connections

1 Gate switch 10 Light curtain (återställnings-

2 Gate reset skydd) station 2
3 Home position/transport indicator 11 Light barrier 2
4 Position indicator for robot/travel 12 Activation unit working area 1
track 13 Timer resetting station 1/ Light
5 Roller door station 1 curtain station 1
6 Roller door station 2 14 Light curtain (återställnings-
7 Operator panel skydd) station 1
8 Activation unit working area 2 15 Light barrier 1
9 Timer resetting station 2/ Light
curtain station 2

504868-05_en.fm 173
Control Cabinet
Interface for operator communications and safety

174 504868-05_en.fm
 Control Cabinet
Interface for operator communications

5.4 Operator communications for positioner types C/R/K

There is a modular based interface fitted to the left of the top cabinet’s rear panel
for operator communications and safety equipment.
The interface includes:
- a circuit card for safety supervision
- a cabling harness prepared for connection of external safety components.


skå[Link]

1 Circuit card for safety supervision SIB

504771-01_en.fm 175
Control Cabinet
Interface for operator communications

Connections
External safety components are connected to the jackable terminal blocks fitted
internally by the two-piece cable glands on the left-hand side of the top cabinet.
Any included standard components are connected according to Figure 40.

1
2
3
3

4 8
7
6

5
Uttag2

Figure 40 Connections

1 Gate switch 5 Operator panel

2 Gate reset 6 Light barrier 1

3 Spare 7 Light curtain station 1

4 Roller door station 1 8 Timer resetting station 1/ Light

curtain station 1

Power supply
The safety equipment is fed with 24V DC from an internal supply unit (24V I/O).
The supply to external safety components is fuse protected internally on the circuit
card for safety supervision and may be loaded with max. 1.5 A continuously.

176 504771-01_en.fm
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Interface for operator communications

5.4.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operator’s panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.

504771-01_en.fm 177
Control Cabinet
Interface for operator communications

The following two figures show the theory behind how the emergency stop loop is
used to control the connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 41 Emergency stop loop

emstopoption

Figure 42 Emergency stop loop with the addition "Extended emergency stop function"

178 504771-01_en.fm
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Interface for operator communications

5.4.2 Interlocks

Operating stop loop

The figure below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"
runchain

Figure 43 Operating stop loop

Two channel break up of the operating stop loops takes place using the circuit card
for safety supervision and the gate switch.
The safety functions on the circuit card are connected to the:
- "GENERAL STOP"
The gate switch is connected to the:
- "AUTO STOP".
In order to run the robot and positioner in the "AUTO" operating mode requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
Operation of the positioner’s station switching unit and work station in the
supervised area is not permitted in the MAN FS (Mode MANUAL - Full speed)
operating mode.

504771-01_en.fm 179
Control Cabinet
Interface for operator communications

Circuit board for supervision

The circuit card includes functions for the supervision of:
- entry protection (light barriers, roller door)
- station mode (limit switch)
- activated positioner axes (engaging and disengaging the motors)

2 1

4
Figur 44 Safety module with option card.

1 Safety module 3 Connection

2 Option card 4 Enclosure

180 504771-01_en.fm
 Control Cabinet
Interface for operator communications

The functions are built up of safety components, where the function and status of
these are supervised via the CAN bus by the control system.
.
8

7
2

6
3

4 5

Figur 45 Module for safety surveillance.

1 Safety relays 5 Fuse

2 DIL switch 6 Voltage regulator
3 Internal connections 7 Voltage regulator
4 External connections 8 CAN-processor

The safety functions can be expanded using different option cards connected to the
circuit card depending on the selected station solution.

5.5 Connection instructions

5.5.1 Connection of the supply voltage

The SIB V module safety circuits are fed with a 24V DC voltage.
- The supply is connected to the jackable terminal TB7.
If necessary, the 0 V level on the supply voltage can be assured by
- connecting a potential equalising conductor to the earth potential in the
environment where the SIB V module is located.

504771-01_en.fm 181
Control Cabinet
Interface for operator communications

Normally the supply is connected to the control cabinet’s voltage supply to the I/O
system (24V I/O, 0V I/O), but the safety system can also be connected to its own
power supply.
The SIB V module’s CAN bus system is galvanically isolated from the other
circuits and receives its supply via the control system’s CAN-bus loop on the
jackable terminal TB6.
The outgoing voltage supply to the connected safety components is fuse protected
internally on the SIB V module and may be loaded with max 1.5 A continuously.
The voltage can be accessed on the jackable terminal TB3.
In Figure 46 - Figure 49 some different connection options to TB7 and TB3 are
shown.

24V I/O 0V I/O

6,%
7%
2 3

Figure 46 Internal voltage supply of the safety module SIB V

24V 0V

6,%
7%
1 2 3

Figure 47 External voltage supply of the safety module SIB V

182 504771-01_en.fm
 Control Cabinet
Interface for operator communications

7%
1 3 2 4

24V 0V
SUPPLY TO STD
SAFETY EQUIPMENT 24V 0V
SUPPLY TO ADDITIONAL
SAFETY EQUIPMENT

Figure 48 Supply to External safety components <1.5A

24V 0V

6,%
7% F
1 2 3

24V 0V
SUPPLY TO SAFETY EQUIPMENT

Figure 49 Supply to External safety components >1.5 A

504771-01_en.fm 183
Control Cabinet
Interface for operator communications

5.5.2 Entry protection

The SIB V module can be configured for the connection of entry protection with
numerous safety output variants. This can be done without adding any extra
components.
Entry protection can consist of:
- light barrier
- light curtain
- door/roller door with safety limit switch
- door/roller door with safety magnetic switch
- pressure mat
- zone detector
The safety outputs can be of the type:
- double NC (normally closed) relay contacts or safety switch contacts
- one NC and one NO (normally open) relay contact or safety switch
contact
- double PNP transistor outputs
- one PNP transistor output and one NPN transistor output
- one PNP transistor output and an INVERTED PNP transistor output
The connected entry protection should be designed to comply with category 4 in
accordance with EN 954-1.

Connection
Connection/configuration of the entry
protection is done on a jackable terminal
located on the top left inside wall of the
cabinet.
- Equipment for area 1 is connected
to X41
- Equipment for area 2 to X42.
Cable entry can easily be made through the
two-piece cover.

184 504771-01_en.fm
 Control Cabinet
Interface for operator communications

The output signals are distributed from the jackable terminals on the entry
protection to the SIB V module as set out in the example in Figure 51.
Note! Input A (24V) must be made at the same time or before input B (0V) in
solutions according to Figure 56 in order to permit resetting of the safety circuit.

*8$5'(48,30HJ/,*+7%($0

“+”
A

“-”
B

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1 3 2 4

24V 0V

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*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 50 Entry protection with relay outputs. The status shown with active protection.

504771-01_en.fm 185
Control Cabinet
Interface for operator communications

*8$5'(48,30HJ+$7&+

A B

;;
1 3 2 4

24V 0V

6,%
7%[ 
n*) n*)

A B

*) DEPENDING ON BOARD TYPE,

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Figure 51 Entry protection with limit switch. The status shown with active protection.

186 504771-01_en.fm
 Control Cabinet
Interface for operator communications

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A B

;;
1 3 2 8 6 5

24V 0V

6,%
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*) DEPENDING ON BOARD TYPE,

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Figure 52 Entry protection with double PNP-outputs

504771-01_en.fm 187
Control Cabinet
Interface for operator communications

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A B

;;
1 3 2 8 6 5

24V 0V

6,%
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*) DEPENDING ON BOARD TYPE,

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Figure 53 Entry protection with one PNP-output and one NPN-output

188 504771-01_en.fm
 Control Cabinet
Interface for operator communications

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A B

;;
1 3 2 7 6 5

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Figure 54 Entry protection with one PNP-output and one INVERTED PNP-output

504771-01_en.fm 189
Control Cabinet
Interface for operator communications

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A B

;;
1 3 2 7 6 5

24V 0V

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Figure 55 Entry protection with one NC and one NO-output. The status shown with active protection
(relay or limit switch)

190 504771-01_en.fm
 Control Cabinet
Interface for operator communications

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A B

;;

On1

On2
In1

In2
1 3 2 4

INPUT INPUT OUTPUT OUTPUT 24V

24V 0V HATCH IS HATCH IS HATCH UP HATCH
UP DOWN DOWN
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AUTO HATCH. OUT

AUTO HATCH. IN

RESET SAFETY
A B

*) DEPENDING ON BOARD TYPE, SEE

ACTUAL SERVICE DIAGRAM

Figure 56 Entry protection - principle for connection of a roller door

504771-01_en.fm 191
Control Cabinet
Interface for operator communications

Resetting
The entry protection is connected to the safety inputs on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection of the entry protection is carried out
as shown in the example.
The input circuits are normally reset using a push-button, located outside of the
risk zone, when the selected entry protection can be passed.
Automatic resetting can be used on protection where this is acceptable from
a safety standpoint.

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24V I/O
PB 1 PB 2

6,%
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ACTIVATE ACTIVATE
AREA 1 AREA2 *)

*) ONLY WHEN BOARD TYPE B3

Figur 57 Manual resetting of entry protection.

192 504771-01_en.fm
 Control Cabinet
Interface for operator communications

Testing
If more protected outputs are required than those available on the SIB V module,
extra relays can be connected in parallel with the relays in the safety circuits on the
SIB V module.
The relays must be approved for safety applications, with positive closing contacts.
The outputs on the SIB V module are fed with 24V DC/0V DC and can be loaded
with max 100 mA.
The operation of the relays can be tested using a NC contact connected to the
resetting circuit for entry protection as set out in the examples in Figure 58 and
Figure 59.

24V

B2
0V

A2

6,% ADDITIONAL SAFETY OUTPUTS

7%
17 18 15 16

TEST INPUT
A B

Figure 58 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 1/2.

24V 24V

B2 B2
0V 0V

A2 A2
ADDITIONAL SAFETY OUTPUTS ADDITIONAL SAFETY OUT

7% 7%
15 16 8 9 15 16 8 9

TEST INPUT TEST INPUT

A B A B

AREA 1 AREA 2

Figure 59 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 3.

Resetting of the protected outputs on the SIB V module will fail if a fault occurs on
any of the relays.

504771-01_en.fm 193
Control Cabinet
Interface for operator communications

5.5.3 Limit switch for the service door

Interlocking of the service door can, depending on the station solution, be
performed with manual or automatically resetting.

Automatic resetting
Automatic resetting is selected when the control cabinet is placed in the immediate
vicinity of the service door so that the operator has a view of the programming area
during the start of the production run.
In this case the limit switch circuits are connected directly to the control cabinet’s
auto-stop-loops.
The auto-stop-loop is reset when:

1 the operator closes the door, for example, after program adjustment and

2 the control system is reset to production mode using:

- the operating mode selector on the control cabinet.
- motors in operation.
The limit switch should be approved
- with double, positive closing and positive opening NC contacts.

194 504771-01_en.fm
 Control Cabinet
Interface for operator communications

Connection example
The circuit breaker is connected to the:
- jackable terminal X92, located on the top left inside wall of the cabinet.
Principle for connection of the limit switch in the safety system is shown in
Figure 60.

6(59,&('225683(59,6,21

;
1 3 2 4

6,%
7%[ 
n*) n*) n*) n*)
ASTOP+

ASTOP-

7%
3 4 7 8

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 60 Service door with automatic resetting of the protection

504771-01_en.fm 195
Control Cabinet
Interface for operator communications

Manual resetting
Manual resetting must be used when the control cabinet’s placement means that the
operator cannot be sure whether someone has passed through the service door after
the operator has left the programming area and moved to the control cabinet to start
the production run.
In this case the SIB V module is supplemented with a safety function that resets
the auto-stop-loops once
- the door is closed and
- the safety functions are reset using a push-button placed on the outside
of the programming area by the service door.
If anyone passes through the door, the operator is not allowed to switch to
production mode before the safety function has been reset again.

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module. The safety circuit is doubled and supervised.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

196 504771-01_en.fm
 Control Cabinet
Interface for operator communications

Connection example
Limit switch and resetting push-button are connected to
- jackable terminals X92 and X91.
The connection principle for the function is shown in Figure 61.

; ;
1 3 2 4 1 2

24V 0V 24V

6,%
7%[ 
n*) n*) n*)
ASTOP+

ASTOP-
A B
A B

7%
3 4 7 8

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 61 Service door with the limit switch - manual resetting of the protection

504771-01_en.fm 197
Control Cabinet
Interface for operator communications

5.5.4 Timer resetting protection

The timer resetting protection is used to prevent anyone remaining in the risk zone
when the entry protection is reset and the ready for start of a new cycle signal is
given to the control system.
This interlock can, for example, be designed as a time function or as a sensing
function.
The offered timer resetting unit consists of
- an option card connected directly to the SIB V module as well as
- an activation push-button, which should be placed within respective risk
zones.

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module. The safety circuit is doubled and supervised.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

198 504771-01_en.fm
 Control Cabinet
Interface for operator communications

Connection example
Connection of the timer resetting protection is done on a jackable terminal located
on the top left inside wall of the cabinet.
- Equipment for area 1 is connected to X81
- Equipment for area 2 to X82.
Cable entry can easily be made through the two-piece cover.
The activation signal is distributed from the jackable terminals to the SIB V
module as set out in the figure below.

5(6(73527(&7,21 35(5(6(7

;;
1 2

24V

6,%
7%[ 
n*) n*) n*)
RES. PROT. OUT

RES. PROT. IN

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 62 Activation push-button for the timer resetting unit

504771-01_en.fm 199
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If some form of sensing unit is used instead of timer resetting protection, a safe
output from this unit must be connected to the SIB V module as set out in the
example in Figure 63.

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&$7$&&72(1

NO JUMPER
CONNECTION!

6,%
7%[ 
n*) n*)
RES. PROT. OUT

RES. PROT. IN

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 63 Timer resetting protection with optional safety unit

The connected sensing unit should be designed to comply with category 4 in

accordance with EN 954-1.

200 504771-01_en.fm
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5.5.5 Movement/station indication for the positioner side

The main functions of the safety switches are
- to detect non-permitted movement on the positioner’s station switching
unit.
Some signals are also used by the I/O system
- to indicate which station side is in position by the robot.

The limit switches are placed in the station switching unit.

Station 2 Station 1

Robot

Station switching unit Limit Switch

Figure 64 Example of station indication on a positioner with a station switching unit and two stations.

Connection
This function is only included on SIB V module types 1 and 2.
Signals from limit switch on the positioner are pre-routed to a jackable terminal on
the safety module.
The terminal can be connected directly to the SIB V module on output TB2. The
signals are utilised by the safety circuits, which activate the control system’s
operating loop.

504771-01_en.fm 201
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Principle solutions for different positioner types are shown in Figure 65 and Figure
66.
Note! The input circuits on the safety switches are
- galvanically isolated from the other safety circuits on the SIB V-module
and
- are fed from the positioner’s positioner interface.
This must be considered when a possible supplement to the safety system is made
so that safety functions are not bypassed due to mixed voltage supplies.

326,7,21(5,17(5&+$1*(683(59,6,21

A B

24V 0V 24V 0V

INPUT INPUT
STN A STN B
AT IRB AT IRB

A B
6,%
7%
9 10 11 12

A1 A2 B1 B2

Figure 65 Supervision of the positioner’s movement and station indication with a 2-station solution

202 504771-01_en.fm
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326,7,21(5,17(5&+$1*(683(59,6,21

A B C D

24V 0V 24V 0V 24V 0V 24V 0V

INPUT INPUT INPUT

STN B STN C STN D
AT IRB AT IRB AT IRB

A B C D
6,%
7%
9 10 11 12 13 14 15 16

A1 A2 B1 B2 C1 C2 D1 D2

Figure 66 Supervision of the positioner’s movement and station indication with a 3/4-station solution

"NOTE!
Equipment used to monitor positioner movement and to indicate the station side
(inputs A - D in the fugures above), should be designed so it cannot switch on the
safety inputs on the SIB V module in the event of a fault arising."

Resetting
The signals from the safety switch are connected to double supervised safety inputs
on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection is carried out as shown in the example.

Testing
The safety circuit is designed so that:
- the limit switch and the input circuits are checked and reset automati-
cally with station switching before a new working cycle is started.

504771-01_en.fm 203
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5.5.6 Station indication for the robot/conveyor

This function is used to
- supervise in which working area the robot is in during production
operations.

Robot
Limit Switch

Station 1 Station 2

Figure 67 Example station indication on the robot with two work stations.

When the limit switches are mounted on the base of the robot these are activated
by a common cam rod.
The switch function results in:
- station indication
- a supervised service position, where the robot can be set, for example,
for cleaning the tool. This area is permanently linked to the 0-position
for the robot’s axis 1 and permits a movement of ±7°.

Robot
Limit Switch

Station 1 Station 2

Service position

Figure 68 Example service position for a robot with two work stations.

204 504771-01_en.fm
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If the function for an installation with the conveyor is used, the safety switches can
instead be mounted on the conveyor’s carriage and are then actuated by individual
cam rods. A service position between work stations is not permitted with this
solution.

Robot Conveyor
Limit Switch

Station 1 Station 2

Figure 69 Example 3 Station indication on the conveyor for the robot with two work stations.

Depending on the selected station solution, the switches can also be mounted on
the base of the robot when a conveyor is included.

504771-01_en.fm 205
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Connection
The switches are connected to jackable terminal X100, located on the top left
inside wall of the cabinet.
Cable entry can easily be made through the two-piece cover.
The output signals from the switches are distributed from the jackable terminals to
the SIB V module as set out in Figure 70.

67$7,21,1',&$7,21:,7+6(59,&(326,7,21

A B

24V 0V

;
1 3 2 4 5 6

24V 0V

6,%
7%
12 13 14 15

A1 A2 B1 B2

Figure 70 Stations supervision IRB/RTT with the limit switch

Resetting and testing

The safety functions for station indication and service position are included as
standard on the SIB V module type 3.
The safety circuit is doubled and supervised and protect against short-circuiting or
hardware failure.
The safety circuit is designed so that
- the limit switch and the input circuits are checked and reset
automatically with movement between station sides, or station side and
the service position, before a new working cycle is started.

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5.5.7 Indication for the home position/transport position

This function is used to
- to supervise that the robot, under production operations, is in a defined
safety area when the selected station solution so demands.
.

Limit Switch
Robot

Home position

Station 1

Figure 71 Example home position for the robot with one work station

Robot
Limit Switch Conveyor

Station 1 Station 2

Figure 72 Example transport position for the robot.

Safety switches are mounted on the base of the robot. They are actuated by an
adjustable cam rod that permits a movement of the robot’s axis 1 by ±20° in the
safe position.
The area can be adjusted by 30° interval around the robot’s axis 1.

504771-01_en.fm 207
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Connection
The switch is connected to
- the jackable terminal X111 located on the top left inside wall of the
cabinet.
Cable entry can easily be made through the two-piece cover.
The output signals from the switches are distributed from the jackable terminals to
the SIB V module as set out in Figure 73.

A B

;
1 2 3 4

24V 0V

6,%
7%
8 9

A B

Figure 73 Supervision of the home position/transport position with the limit switch

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module.
Note! This function only works with the SIB V module type 3.
The safety circuit is doubled and supervised and protects against short-circuiting or
hardware failure.
The safety circuit is designed so that
- the limit switch and the input circuits are checked and reset
automatically with movement to and from the home position/transport
position before a new working cycle is started.

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5.5.8 Activation unit

An activation unit is used when there is a need to activate the activate work station
from the operator’s area, for example, programming, fixture replacement, etc.
Activation is performed using a separate push-button, which is located inside the
supervised area. Activation can only be done in manual operating mode.
- MANUAL REDUCED SPEED (<250 mm/s)
100%
- MANUAL FULL SPEED 100%
The SIB V module type 3 is equipped with the input circuits for reception of the
activation signal. This can be done without adding any extra components.

Resetting
The activation unit is connected to the supervised safety inputs on the SIB V
module.
The input circuits are normally reset with
- a push-button that is located inside the entry protection and out of the
reach from the outside of the activated entry protection.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

504771-01_en.fm 209
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Connection example
Connection of the activation push-button is done on a jackable terminal located on
the top left inside wall of the cabinet.
- Equipment for area 1 is connected to X93
- Equipment for area 2 to X94.
Cable entry can easily be made through the two-piece cover.
The activation signals are distributed from the respective push-buttons via the
jackable terminals to the SIB V module as set out in the example in Figure 74.

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)52023(5$725$5($

;;
1 2

24VMAN /
MAN FS
6,%
7%7%
18

TO RESET RELAY
GUARD EQ.

Figure 74 The activation push-button for programming from the operator’s area

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5.5.9 Operating loop, operating principles and connection possibilities

The SIB V module’s supervision circuits are connected to the control system’s
operating loop with doubled and supervised safety outputs.
Depending on the safety function these outputs are activated:
- operating loop’s auto stop or
- general stop level.
The operating loop is connected to the SIB V module on the jackable terminal TB1
according to Figure 75.

GS1+ 24V AS2+ GS2- 0V AS1-

6,%
7%
1 2 3 4 5 6 7 8

A A B B

SAFETY FUNCT. SAFETY FUNCT. SAFETY FUNCT. SAFETY FUNCT.

GENERAL STOP CH.1 AUTO STOP CH.1 GENERAL STOP CH.2 AUTO STOP CH.2

Figure 75 The operating loop’s connection to the safety system

504771-01_en.fm 211
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The operating principle for the protection function’s activation of the auto stop and
general stop level are shown in Figure 76 and Figure 77.

GENERAL AUTO
STOP V-SUPPLY STOP

6,%
7%
n n n n

ICH. GUARD SERVICE

POS. EQ. DOOR
LOAD MODE
STN. SEL. SW.
ICH.
UNIT

Figure 76 The safety function’s design for the safety module SIB-V type 1/2

GENERAL AUTO
STOP V-SUPPLY STOP

6,%
7%
n n n n

HOME / IRB/RTT GUARD SERVICE

TRANSP. POS. EQ. DOOR
AREA 2 POS.
LOAD
STN.

HOME / IRB/RTT GUARD

TRANSP. POS. EQ.
AREA 1 POS. LOAD
STN.

Figure 77 The safety function’s design for the safety module SIB-V type 3

212 504771-01_en.fm
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In addition to the SIB V-module’s safety functions it is possible to connect further

external safety functions to the break-out points in the supervision circuits. This
permits the station solution to be adapted to satisfy a customer’s wishes.
The connected safety function should be designed to comply with category 4 in
accordance with EN 954-1.
In Figure 78 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V module type 1 /2 and some examples of how these can be used are
also shown.
Note! The break-out points are normally strapped on delivery.

OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT.

IN PARALLELL IN SERIAL WITH IN PARALLELL IN SERIAL WITH
WITH ICH. POS / SAFETY WITH [Link] / SAFETY
LOAD STN FUNCTIONS *) LOAD STN FUNCTIONS *)

6,%
7%
9 10 11 12 15 16 17 18

GSTOP GSTOP GSTOP GSTOP

CH.1 CH.1 CH.2 CH.2

*) TERMINALS USED FOR SAFETY

FUNCTION IN RUN CHAIN WHEN
SIB-BOARD TYPE 2

Figure 78 The break-out points for the operating loop safety module SIB-V type 1/2

In Figure 79 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V-module type 3 and some examples of how these can be used are
also shown.

OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT.
IN PARALLELL IN PARALLELL IN SERIAL WITH IN PARALLELL IN PARALLELL IN SERIAL WITH
WITH IRB/RTT POS / WITH IRB/RTT POS / SAFETY WITH IRB/RTT POS / WITH IRB/RTT POS / SAFETY
LOAD STN - AREA1 LOAD STN - AREA2 FUNCTIONS LOAD STN - AREA1 LOAD STN - AREA2 FUNCTIONS

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

GSTOP GSTOP GSTOP GSTOP GSTOP GSTOP

CH.1 CH.1 CH.1 CH.2 CH.2 CH.2

Figure 79 The break-out points for the operating loop safety module SIB-V type 3

504771-01_en.fm 213
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Figure 80 illustrates connection examples of the protection between the program-

ming area, for example, inner light beam (status shown with active protection) for
safety module SIB-V type 1/2.
Note! safety outputs for e.g. fixture interlocking are used!

*8$5'(48,30HJ/,*+7%($0
&$7$&&72(1

“+”
A

“-”
B

6,%
7% 7%
11 12 17 18 1 2 3 4

GSTOP GSTOP
CH.1 CH.2
OPTIONAL FUNCT. OPTIONAL FUNCT.
IN SERIAL WITH IN SERIAL WITH
SAFETY SAFETY AREA 1 AREA 1
FUNCTIONS FUNCTIONS CH.A CH.B

Figure 80 Examples of connecting the entry protection between the programming area.

214 504771-01_en.fm
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Interface for operator communications

Figure 81 illustrates connection examples of entry protection between the operator

area 1 and operator area 2; the status is shown with active protection, for safety
module SIB-V typ 3.
Bypass passage is only permitted in operating mode MAN/ MAN FS.
Note! safety outputs for e.g. fixture interlocking are used!

*8$5'(48,30HJ/,*+7%($0
&$7$&&72(1

“+”
A

“-”
B
NY

6,%
7% 7%
5 6 11 12 1 2 9 10 3 4 11 12

GSTOP GSTOP
CH.1 CH.2
OPTIONAL FUNCT. OPTIONAL FUNCT.
IN SERIAL WITH IN SERIAL WITH AREA 1 AREA 1
AREA 2 AREA 2
SAFETY SAFETY
FUNCTIONS FUNCTIONS CH.A CH.A CH.B CH.B

Figure 81 Examples of connecting entry protection between operator area 1 and operator area 2.

504771-01_en.fm 215
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5.5.10 Safety outputs for customer connections

The SIB V module contains a number of free safety outputs that can be used to
safely control and supervise your own equipment.
Jackable terminal TB4: Acknowledgement outputs activated process/resetting
entry protection.
- The outputs can be utilised for signals, for example, PLC and may be
loaded with max. 24V DC, 50mA(??).
Jackable terminal TB5: These outputs can be used, for example, in the design of
safety circuits for fixture control.
- Each output can be loaded with a maximum of 24V DC, 2A.
In Figure 82 - Figure 86 some examples of how the outputs, as set out above, can
be used for different station solutions are shown.
Note! Some applications demand that the signal interface is supplemented with the
option “extended emergency stop”.

6,%
7%
5 6 2 3

ACTIVATE ACTIVATE
AREA 1 AREA 2

Figure 82 Safety outputs for acknowledgement of entry protection resetting, max. 50 mA

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

AREA 1 AREA 1 STN 1 STN 2 STN 3*) STN 4*)

CH.A CH.B

*) ONLY WHEN BOARD TYPE B2

Figure 83 Safety outputs for safety module SIB-V type 1/2, max. 2 A

216 504771-01_en.fm
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6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

AREA 1 AREA 1 STN 1 STN 2 AREA 2 AREA 2

CH.B CH.A CH.B
CH.A

Figure 84 Safety outputs for safety module SIB-V type 3, max. 2 A

PNEUM. VALVE PNEUM. VALVE

AIR SUPPLY AIR SUPPLY
STN1 STN2

1 2

2
SAFETY RELAYS
B

B 1
A B 1 2
A
A

7% 7%
1 2 3 4 5 6 7 8 15 16
EM.
TEST INPUT STOP
CH.B
EM.
AREA 1 AREA 1 STN 1 STN 2 STOP
CH.A CH.B CH.A
7%
5 6

2 1 1 2
In1

In2

On1

On2

OUTPUT(S) OUTPUT(S)
CLAMP CLAMP
VALVE(S) VALVE(S)
STN 1 STN 2

Figure 85 Example of the fixture interlock principle with safety module SIB-V type 1

504771-01_en.fm 217
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PNEUM. VALVE PNEUM. VALVE

AIR SUPPLY AIR SUPPLY
STN1 STN2

1 2

SAFETY RELAYS
1B 2B

1A 1B 1 2 2A 2B
1A 2A

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12
EM.
STOP
CH.B
EM.
AREA 1 AREA 1 STN 1 STN 2 AREA 2 AREA 2 STOP
CH.B CH.A CH.B CH.A
CH.A
TEST INPUT TEST INPUT

7% 7% 7%

5 6 2 3 8 9 8 9

1B 2B 1 2

On1

On2
In1

In2

1A 2A
INPUT INPUT OUTPUT(S) OUTPUT(S)
ACTIVATE ACTIVATE CLAMP CLAMP
CLAMP CLAMP VALVE(S) VALVE(S)
VALVES VALVES STN 1 STN 2
STN 1 STN 2

Figure 86 Example of the fixture interlock principle with safety module SIB-V type 3

218 504771-01_en.fm
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5.6 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

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504 771-880 Operatö[Link]änss- Operator communica-
nitt tion InterFace

11 504 949-880 Plåt, kompl. Plate, compl.

15 504 994-880 Säkerhetskort V, Typ 1 SafetyInterfaceBoard V, SIB
Type 1
17 489 947-469 Anslutningsdon, Combi- Connector, Combicon 7 pol
con
18 500 958-001 Insticksbrygga Bridge 7 pol

20 436 829-009 Jordklämma Terminal

41 502 291-880 Kabelstam Cable harness

504771-01_en.fm 219
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15
11

41
17
18
504771a01

20

220 504771-01_en.fm
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504771-01_en.fm 221
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222 504771-01_en.fm
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5.7 Operator communication for positioner types A/L/S

There is a modular based interface fitted to the right of the cabinet’s rear panel for
operator communications and safety equipment.
The interface includes:
- a circuit card for safety supervision
- a cabling harness prepared for connection of external safety components.
The interface can be used for supervision of one or two work stations without
further modification depending on the selected station solution.


skå[Link]

Figure 87

1 Circuit card for safety supervision SIB

504773-01_en.fm 223
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Connections
External safety components are connected to the jackable terminal blocks fitted
internally by the two-piece cable glands on the left-hand side of the top cabinet.
Any included standard components are connected according to Figure 88.

1 8
2 9
3 10
4 11

12
13
5
14
6 15

7
Uttag2

Figure 88 Connections

1 Gate switch 10 Light curtain (återställningsskydd)

2 Gate reset station 2
3 Home position/transport indicator 11 Light barrier 2
4 Position indicator for robot/travel 12 Activation unit working area 1
track 13 Timer resetting station 1/ Light curtain
5 Roller door station 1 station 1
6 Roller door station 2 14 Light curtain (återställningsskydd)
7 Operator panel station 1
8 Activation unit working area 2 15 Light barrier 1
9 Timer resetting station 2/ Light
curtain station 2

Power supply
The safety equipment is fed with 24V DC from an internal supply unit (24V I/O).
The supply to external safety components is fuse protected internally on the circuit
card for safety supervision and may be loaded with max. 1.5 A continuously.

224 504773-01_en.fm
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5.7.1 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operator’s panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.

504773-01_en.fm 225
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The following two figures show the theory behind how the emergency stop loop is
used to control the connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 89 Emergency stop loop

emstopoption

Figure 90 Emergency stop loop with the addition "Extended emergency stop function"

226 504773-01_en.fm
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5.7.2 Interlocks

Operating stop loop

The figure below shows the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"
runchain

Figure 91 Operating stop loop

Two channel break up of the operating stop loops takes place using the circuit card
for safety supervision and the gate switch.
The safety functions on the circuit card are connected to the:
- "GENERAL STOP"
The gate switch is connected to the:
- "AUTO STOP".
In order to run the robot and positioner in the "AUTO" operating mode requires:
- all safety loops to be intact and
- that the system has been started (MOTORS_ON).
Operation of the positioner’s station switching unit and work station in the
supervised area is not permitted in the MAN FS (Mode MANUAL - Full speed)
operating mode.

504773-01_en.fm 227
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Circuit board for supervision

The circuit card includes functions for the supervision of:
- entry protection (light barriers, roller door)
- station mode (limit switch)
- activated positioner axes (engaging and disengaging the motors)

2 1

4
Figur 92 Safety module with option card.

1 Safety module 3 Connection

2 Option card 4 Enclosure

228 504773-01_en.fm
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The functions are built up of safety components, where the function and status of
these are supervised via the CAN bus by the control system.
.
8

7
2

6
3

4 5

Figur 93 Module for safety surveillance.

1 Safety relays 5 Fuse

2 DIL switch 6 Voltage regulator
3 Internal connections 7 Voltage regulator
4 External connections 8 CAN-processor

The safety functions can be expanded using different option cards connected to the
circuit card depending on the selected station solution.

5.8 Connection instructions

5.8.1 Connection of the supply voltage

The SIB V module safety circuits are fed with a 24V DC voltage.
- The supply is connected to the jackable terminal TB7.
If necessary, the 0 V level on the supply voltage can be assured by
- connecting a potential equalising conductor to the earth potential in the
environment where the SIB V module is located.

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Normally the supply is connected to the control cabinet’s voltage supply to the I/O
system (24V I/O, 0V I/O), but the safety system can also be connected to its own
power supply.
The SIB V module’s CAN bus system is galvanically isolated from the other
circuits and receives its supply via the control system’s CAN-bus loop on the
jackable terminal TB6.
The outgoing voltage supply to the connected safety components is fuse protected
internally on the SIB V module and may be loaded with max 1.5 A continuously.
The voltage can be accessed on the jackable terminal TB3.
In Figure 94 - Figure 97 some different connection options to TB7 and TB3 are
shown.

24V I/O 0V I/O

6,%
7%
2 3

Figure 94 Internal voltage supply of the safety module SIB V

24V 0V

6,%
7%
1 2 3

Figure 95 External voltage supply of the safety module SIB V

230 504773-01_en.fm
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7%
1 3 2 4

24V 0V
SUPPLY TO STD
SAFETY EQUIPMENT 24V 0V
SUPPLY TO ADDITIONAL
SAFETY EQUIPMENT

Figure 96 Supply to External safety components <1.5A

24V 0V

6,%
7% F
1 2 3

24V 0V
SUPPLY TO SAFETY EQUIPMENT

Figure 97 Supply to External safety components >1.5 A

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5.8.2 Entry protection

The SIB V module can be configured for the connection of entry protection with
numerous safety output variants. This can be done without adding any extra
components.
Entry protection can consist of:
- light barrier
- light curtain
- door/roller door with safety limit switch
- door/roller door with safety magnetic switch
- pressure mat
- zone detector
The safety outputs can be of the type:
- double NC (normally closed) relay contacts or safety switch contacts
- one NC and one NO (normally open) relay contact or safety switch
contact
- double PNP transistor outputs
- one PNP transistor output and one NPN transistor output
- one PNP transistor output and an INVERTED PNP transistor output
The connected entry protection should be designed to comply with category 4 in
accordance with EN 954-1.

Connection
Connection/configuration of the entry
protection is done on a jackable terminal
located on the top left inside wall of the
cabinet.
- Equipment for area 1 is connected
to X41
- Equipment for area 2 to X42.
Cable entry can easily be made through the
two-piece cover.

232 504773-01_en.fm
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The output signals are distributed from the jackable terminals on the entry
protection to the SIB V module as set out in the example in Figure 99.
Note! Input A (24V) must be made at the same time or before input B (0V) in
solutions according to Figure 104 in order to permit resetting of the safety circuit.

*8$5'(48,30HJ/,*+7%($0

“+”
A

“-”
B

;;
1 3 2 4

24V 0V

6,%
7%[ 
n*) n*)

A B

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 98 Entry protection with relay outputs. The status shown with active protection.

504773-01_en.fm 233
Control Cabinet
Interface for operator communications

*8$5'(48,30HJ+$7&+

A B

;;
1 3 2 4

24V 0V

6,%
7%[ 
n*) n*)

A B

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 99 Entry protection with limit switch. The status shown with active protection.

234 504773-01_en.fm
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*8$5'(48,30HJ/,*+7%($0

A B

;;
1 3 2 8 6 5

24V 0V

6,%
7%[ 
n*) n*) n*) n*)

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 100 Entry protection with double PNP-outputs

504773-01_en.fm 235
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*8$5'(48,30HJ/,*+7%($0

A B

;;
1 3 2 8 6 5

24V 0V

6,%
7%[ 
n*) n*) n*) n*)

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 101 Entry protection with one PNP-output and one NPN-output

236 504773-01_en.fm
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*8$5'(48,30HJ/,*+7%($0

A B

;;
1 3 2 7 6 5

24V 0V

6,%
7%[ 
n*) n*) n*) n*)

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 102 Entry protection with one PNP-output and one INVERTED PNP-output

504773-01_en.fm 237
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*8$5'(48,30HJ/,*+7%($0

A B

;;
1 3 2 7 6 5

24V 0V

6,%
7%[ 
n*) n*) n*) n*)

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 103 Entry protection with one NC and one NO-output. The status shown with active protection
(relay or limit switch)

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*8$5'(48,30 02725+$7&+

A B

;;

On1

On2
In1

In2
1 3 2 4

INPUT INPUT OUTPUT OUTPUT 24V

24V 0V HATCH IS HATCH IS HATCH UP HATCH
UP DOWN DOWN
6,%
7%[ 
n*) n*) n*) n*) n*)

AUTO HATCH. OUT

AUTO HATCH. IN

RESET SAFETY
A B

*) DEPENDING ON BOARD TYPE, SEE

ACTUAL SERVICE DIAGRAM

Figure 104 Entry protection - principle for connection of a roller door

504773-01_en.fm 239
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Resetting
The entry protection is connected to the safety inputs on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection of the entry protection is carried out
as shown in the example.
The input circuits are normally reset using a push-button, located outside of the
risk zone, when the selected entry protection can be passed.
Automatic resetting can be used on protection where this is acceptable from
a safety standpoint.

*8$5'(48,30(17 0$18$/5(6(7

24V I/O
PB 1 PB 2

6,%
7%
4 1

ACTIVATE ACTIVATE
AREA 1 AREA2 *)

*) ONLY WHEN BOARD TYPE B3

Figur 105 Manual resetting of entry protection.

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Testing
If more protected outputs are required than those available on the SIB V module,
extra relays can be connected in parallel with the relays in the safety circuits on the
SIB V module.
The relays must be approved for safety applications, with positive closing contacts.
The outputs on the SIB V module are fed with 24V DC/0V DC and can be loaded
with max 100 mA.
The operation of the relays can be tested using a NC contact connected to the
resetting circuit for entry protection as set out in the examples in Figure 106 and
Figure 107.

24V

B2
0V

A2

6,% ADDITIONAL SAFETY OUTPUTS

7%
17 18 15 16

TEST INPUT
A B

Figure 106 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 1/2.

24V 24V

B2 B2
0V 0V

A2 A2
ADDITIONAL SAFETY OUTPUTS ADDITIONAL SAFETY OUT

7% 7%
15 16 8 9 15 16 8 9

TEST INPUT TEST INPUT

A B A B

AREA 1 AREA 2

Figure 107 Connection and testing of the extra safety relay for entry protection.
Applies to safety module SIB-V, type 3.

Resetting of the protected outputs on the SIB V module will fail if a fault occurs on
any of the relays.

504773-01_en.fm 241
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5.8.3 Limit switch for the service door

Interlocking of the service door can, depending on the station solution, be
performed with manual or automatically resetting.

Automatic resetting
Automatic resetting is selected when the control cabinet is placed in the immediate
vicinity of the service door so that the operator has a view of the programming area
during the start of the production run.
In this case the limit switch circuits are connected directly to the control cabinet’s
auto-stop-loops.
The auto-stop-loop is reset when:

1 the operator closes the door, for example, after program adjustment and

2 the control system is reset to production mode using:

- the operating mode selector on the control cabinet.
- motors in operation.
The limit switch should be approved
- with double, positive closing and positive opening NC contacts.

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Connection example
The circuit breaker is connected to the:
- jackable terminal X92, located on the top left inside wall of the cabinet.
Principle for connection of the limit switch in the safety system is shown in
Figure 108.

6(59,&('225683(59,6,21

;
1 3 2 4

6,%
7%[ 
n*) n*) n*) n*)
ASTOP+

ASTOP-

7%
3 4 7 8

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 108 Service door with automatic resetting of the protection

504773-01_en.fm 243
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Manual resetting
Manual resetting must be used when the control cabinet’s placement means that the
operator cannot be sure whether someone has passed through the service door after
the operator has left the programming area and moved to the control cabinet to start
the production run.
In this case the SIB V module is supplemented with a safety function that resets
the auto-stop-loops once
- the door is closed and
- the safety functions are reset using a push-button placed on the outside
of the programming area by the service door.
If anyone passes through the door, the operator is not allowed to switch to
production mode before the safety function has been reset again.

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module. The safety circuit is doubled and supervised.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

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Connection example
Limit switch and resetting push-button are connected to
- jackable terminals X92 and X91.
The connection principle for the function is shown in Figure 109.

; ;
1 3 2 4 1 2

24V 0V 24V

6,%
7%[ 
n*) n*) n*)
ASTOP+

ASTOP-
A B
A B

7%
3 4 7 8

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 109 Service door with the limit switch - manual resetting of the protection

504773-01_en.fm 245
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5.8.4 Timer resetting protection

The timer resetting protection is used to prevent anyone remaining in the risk zone
when the entry protection is reset and the ready for start of a new cycle signal is
given to the control system.
This interlock can, for example, be designed as a time function or as a sensing
function.
The offered timer resetting unit consists of
- an option card connected directly to the SIB V module as well as
- an activation push-button, which should be placed within respective risk
zones.

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module. The safety circuit is doubled and supervised.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

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Connection example
Connection of the timer resetting protection is done on a jackable terminal located
on the top left inside wall of the cabinet.
- Equipment for area 1 is connected to X81
- Equipment for area 2 to X82.
Cable entry can easily be made through the two-piece cover.
The activation signal is distributed from the jackable terminals to the SIB V
module as set out in the figure below.

5(6(73527(&7,21 35(5(6(7

;;
1 2

24V

6,%
7%[ 
n*) n*) n*)
RES. PROT. OUT

RES. PROT. IN

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 110 Activation push-button for the timer resetting unit

504773-01_en.fm 247
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If some form of sensing unit is used instead of timer resetting protection, a safe
output from this unit must be connected to the SIB V module as set out in the
example in Figure 111.

5(6(73527(&7,21 6$)(7<'(9,&(HJ/,*+7&857$,1
&$7$&&72(1

NO JUMPER
CONNECTION!

6,%
7%[ 
n*) n*)
RES. PROT. OUT

RES. PROT. IN

*) DEPENDING ON BOARD TYPE,

SEE ACTUAL SERVICE DIAGRAM

Figure 111 Timer resetting protection with optional safety unit

The connected sensing unit should be designed to comply with category 4 in

accordance with EN 954-1.

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5.8.5 Movement/station indication for the positioner side

The main functions of the safety switches are
- to detect non-permitted movement on the positioner’s station switching
unit.
Some signals are also used by the I/O system
- to indicate which station side is in position by the robot.

The limit switches are placed in the station switching unit.

Station 2 Station 1

Robot

Station switching unit Limit Switch

Figure 112 Example of station indication on a positioner with a station switching unit and two stations.

Connection
This function is only included on SIB V module types 1 and 2.
Signals from limit switch on the positioner are pre-routed to a jackable terminal on
the safety module.
The terminal can be connected directly to the SIB V module on output TB2. The
signals are utilised by the safety circuits, which activate the control system’s
operating loop.

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Principle solutions for different positioner types are shown in Figure 113 and
Figure 114.
Note! The input circuits on the safety switches are
- galvanically isolated from the other safety circuits on the SIB V-module
and
- are fed from the positioner’s positioner interface.
This must be considered when a possible supplement to the safety system is made
so that safety functions are not bypassed due to mixed voltage supplies.

326,7,21(5,17(5&+$1*(683(59,6,21

A B

24V 0V 24V 0V

INPUT INPUT
STN A STN B
AT IRB AT IRB

A B
6,%
7%
9 10 11 12

A1 A2 B1 B2

Figure 113 Supervision of the positioner’s movement and station indication with a 2-station solution

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326,7,21(5,17(5&+$1*(683(59,6,21

A B C D

24V 0V 24V 0V 24V 0V 24V 0V

INPUT INPUT INPUT

STN B STN C STN D
AT IRB AT IRB AT IRB

A B C D
6,%
7%
9 10 11 12 13 14 15 16

A1 A2 B1 B2 C1 C2 D1 D2

Figure 114 Supervision of the positioner’s movement and station indication with a 3/4-station solution

"NOTE!
Equipment used to monitor positioner movement and to indicate the station side
(inputs A - D in the fugures above), should be designed so it cannot switch on the
safety inputs on the SIB V module in the event of a fault arising."

Resetting
The signals from the safety switch are connected to double supervised safety inputs
on the SIB V module.
These input circuits are doubled and supervised as well as protected against short
circuiting or hardware failure if connection is carried out as shown in the example.

Testing
The safety circuit is designed so that:
- the limit switch and the input circuits are checked and reset automati-
cally with station switching before a new working cycle is started.

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5.8.6 Station indication for the robot/conveyor

This function is used to
- supervise in which working area the robot is in during production
operations.

Robot
Limit Switch

Station 1 Station 2

Figure 115 Example station indication on the robot with two work stations.

When the limit switches are mounted on the base of the robot these are activated
by a common cam rod.
The switch function results in:
- station indication
- a supervised service position, where the robot can be set, for example,
for cleaning the tool. This area is permanently linked to the 0-position
for the robot’s axis 1 and permits a movement of ±7°.

Robot
Limit Switch

Station 1 Station 2

Service position

Figure 116 Example service position for a robot with two work stations.

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If the function for an installation with the conveyor is used, the safety switches can
instead be mounted on the conveyor’s carriage and are then actuated by individual
cam rods. A service position between work stations is not permitted with this
solution.

Robot Conveyor
Limit Switch

Station 1 Station 2

Figure 117 Example 3 Station indication on the conveyor for the robot with two work stations.

Depending on the selected station solution, the switches can also be mounted on
the base of the robot when a conveyor is included.

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Connection
The switches are connected to jackable terminal X100, located on the top left
inside wall of the cabinet.
Cable entry can easily be made through the two-piece cover.
The output signals from the switches are distributed from the jackable terminals to
the SIB V module as set out in Figure 118.

67$7,21,1',&$7,21:,7+6(59,&(326,7,21

A B

24V 0V

;
1 3 2 4 5 6

24V 0V

6,%
7%
12 13 14 15

A1 A2 B1 B2

Figure 118 Stations supervision IRB/RTT with the limit switch

Resetting and testing

The safety functions for station indication and service position are included as
standard on the SIB V module type 3.
The safety circuit is doubled and supervised and protect against short-circuiting or
hardware failure.
The safety circuit is designed so that
- the limit switch and the input circuits are checked and reset
automatically with movement between station sides, or station side and
the service position, before a new working cycle is started.

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5.8.7 Indication for the home position/transport position

This function is used to
- to supervise that the robot, under production operations, is in a defined
safety area when the selected station solution so demands.
.

Limit Switch
Robot

Home position

Station 1

Figure 119 Example home position for the robot with one work station

Robot
Limit Switch Conveyor

Station 1 Station 2

Figure 120 Example transport position for the robot.

Safety switches are mounted on the base of the robot. They are actuated by an
adjustable cam rod that permits a movement of the robot’s axis 1 by ±20° in the
safe position.
The area can be adjusted by 30° interval around the robot’s axis 1.

504773-01_en.fm 255
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Connection
The switch is connected to
- the jackable terminal X111 located on the top left inside wall of the
cabinet.
Cable entry can easily be made through the two-piece cover.
The output signals from the switches are distributed from the jackable terminals to
the SIB V module as set out in Figure 121.

A B

;
1 2 3 4

24V 0V

6,%
7%
8 9

A B

Figure 121 Supervision of the home position/transport position with the limit switch

Resetting and testing

The safety function consists of an option card, which is connected to the SIB V
module.
Note! This function only works with the SIB V module type 3.
The safety circuit is doubled and supervised and protects against short-circuiting or
hardware failure.
The safety circuit is designed so that
- the limit switch and the input circuits are checked and reset
automatically with movement to and from the home position/transport
position before a new working cycle is started.

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5.8.8 Activation unit

An activation unit is used when there is a need to activate the activate work station
from the operator’s area, for example, programming, fixture replacement, etc.
Activation is performed using a separate push-button, which is located inside the
supervised area. Activation can only be done in manual operating mode.
- MANUAL REDUCED SPEED (<250 mm/s)
100%
- MANUAL FULL SPEED 100%
The SIB V module type 3 is equipped with the input circuits for reception of the
activation signal. This can be done without adding any extra components.

Resetting
The activation unit is connected to the supervised safety inputs on the SIB V
module.
The input circuits are normally reset with
- a push-button that is located inside the entry protection and out of the
reach from the outside of the activated entry protection.
The input from the push-button is protected against short-circuiting as this must be
both closed and opened in order for the safety circuits’ outputs to be reset.

504773-01_en.fm 257
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Connection example
Connection of the activation push-button is done on a jackable terminal located on
the top left inside wall of the cabinet.
- Equipment for area 1 is connected to X93
- Equipment for area 2 to X94.
Cable entry can easily be made through the two-piece cover.
The activation signals are distributed from the respective push-buttons via the
jackable terminals to the SIB V module as set out in the example in Figure 122.

$&7,9$7,2181,7 352*5$00,1*
)52023(5$725$5($

;;
1 2

24VMAN /
MAN FS
6,%
7%7%
18

TO RESET RELAY
GUARD EQ.

Figure 122 The activation push-button for programming from the operator’s area

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5.8.9 Operating loop, operating principles and connection possibilities

The SIB V module’s supervision circuits are connected to the control system’s
operating loop with doubled and supervised safety outputs.
Depending on the safety function these outputs are activated:
- operating loop’s auto stop or
- general stop level.
The operating loop is connected to the SIB V module on the jackable terminal TB1
according to Figure 123.

GS1+ 24V AS2+ GS2- 0V AS1-

6,%
7%
1 2 3 4 5 6 7 8

A A B B

SAFETY FUNCT. SAFETY FUNCT. SAFETY FUNCT. SAFETY FUNCT.

GENERAL STOP CH.1 AUTO STOP CH.1 GENERAL STOP CH.2 AUTO STOP CH.2

Figure 123 The operating loop’s connection to the safety system

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The operating principle for the protection function’s activation of the auto stop and
general stop level are shown in Figure 124 and Figure 125.

GENERAL AUTO
STOP V-SUPPLY STOP

6,%
7%
n n n n

ICH. GUARD SERVICE

POS. EQ. DOOR
LOAD MODE
STN. SEL. SW.
ICH.
UNIT

Figure 124 The safety function’s design for the safety module SIB-V type 1/2

GENERAL AUTO
STOP V-SUPPLY STOP

6,%
7%
n n n n

HOME / IRB/RTT GUARD SERVICE

TRANSP. POS. EQ. DOOR
AREA 2 POS.
LOAD
STN.

HOME / IRB/RTT GUARD

TRANSP. POS. EQ.
AREA 1 POS. LOAD
STN.

Figure 125 The safety function’s design for the safety module SIB-V type 3

260 504773-01_en.fm
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In addition to the SIB V-module’s safety functions it is possible to connect further

external safety functions to the break-out points in the supervision circuits. This
permits the station solution to be adapted to satisfy a customer’s wishes.
The connected safety function should be designed to comply with category 4 in
accordance with EN 954-1.
In Figure 126 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V module type 1 /2 and some examples of how these can be used are
also shown.
Note! The break-out points are normally strapped on delivery.

OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT.

IN PARALLELL IN SERIAL WITH IN PARALLELL IN SERIAL WITH
WITH ICH. POS / SAFETY WITH [Link] / SAFETY
LOAD STN FUNCTIONS *) LOAD STN FUNCTIONS *)

6,%
7%
9 10 11 12 15 16 17 18

GSTOP GSTOP GSTOP GSTOP

CH.1 CH.1 CH.2 CH.2

*) TERMINALS USED FOR SAFETY

FUNCTION IN RUN CHAIN WHEN
SIB-BOARD TYPE 2

Figure 126 The break-out points for the operating loop safety module SIB-V type 1/2

In Figure 127 the break-out points are shown on the jackable terminals TB32 and
TB34 for SIB V-module type 3 and some examples of how these can be used are
also shown.

OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT. OPTIONAL FUNCT.
IN PARALLELL IN PARALLELL IN SERIAL WITH IN PARALLELL IN PARALLELL IN SERIAL WITH
WITH IRB/RTT POS / WITH IRB/RTT POS / SAFETY WITH IRB/RTT POS / WITH IRB/RTT POS / SAFETY
LOAD STN - AREA1 LOAD STN - AREA2 FUNCTIONS LOAD STN - AREA1 LOAD STN - AREA2 FUNCTIONS

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

GSTOP GSTOP GSTOP GSTOP GSTOP GSTOP

CH.1 CH.1 CH.1 CH.2 CH.2 CH.2

Figure 127 The break-out points for the operating loop safety module SIB-V type 3

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Figure 128 illustrates connection examples of the protection between the program-
ming area, for example, inner light beam (status shown with active protection) for
safety module SIB-V type 1/2.
Note! safety outputs for e.g. fixture interlocking are used!

*8$5'(48,30HJ/,*+7%($0
&$7$&&72(1

“+”
A

“-”
B

6,%
7% 7%
11 12 17 18 1 2 3 4

GSTOP GSTOP
CH.1 CH.2
OPTIONAL FUNCT. OPTIONAL FUNCT.
IN SERIAL WITH IN SERIAL WITH
SAFETY SAFETY AREA 1 AREA 1
FUNCTIONS FUNCTIONS CH.A CH.B

Figure 128 Examples of connecting the entry protection between the programming area.

262 504773-01_en.fm
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Figure 129 illustrates connection examples of entry protection between the opera-
tor area 1 and operator area 2; the status is shown with active protection, for safety
module SIB-V typ 3.
Bypass passage is only permitted in operating mode MAN/ MAN FS.
Note! safety outputs for e.g. fixture interlocking are used!

*8$5'(48,30HJ/,*+7%($0
&$7$&&72(1

“+”
A

“-”
B
NY

6,%
7% 7%
5 6 11 12 1 2 9 10 3 4 11 12

GSTOP GSTOP
CH.1 CH.2
OPTIONAL FUNCT. OPTIONAL FUNCT.
IN SERIAL WITH IN SERIAL WITH AREA 1 AREA 1
AREA 2 AREA 2
SAFETY SAFETY
FUNCTIONS FUNCTIONS CH.A CH.A CH.B CH.B

Figure 129 Examples of connecting entry protection between operator area 1 and operator area 2.

504773-01_en.fm 263
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5.8.10 Safety outputs for customer connections

The SIB V module contains a number of free safety outputs that can be used to
safely control and supervise your own equipment.
Jackable terminal TB4: Acknowledgement outputs activated process/resetting
entry protection.
- The outputs can be utilised for signals, for example, PLC and may be
loaded with max. 24V DC, 50mA(??).
Jackable terminal TB5: These outputs can be used, for example, in the design of
safety circuits for fixture control.
- Each output can be loaded with a maximum of 24V DC, 2A.
In Figure 130 - Figure 134 some examples of how the outputs, as set out above,
can be used for different station solutions are shown.
Note! Some applications demand that the signal interface is supplemented with the
option “extended emergency stop”.

6,%
7%
5 6 2 3

ACTIVATE ACTIVATE
AREA 1 AREA 2

Figure 130 Safety outputs for acknowledgement of entry protection resetting, max. 50 mA

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

AREA 1 AREA 1 STN 1 STN 2 STN 3*) STN 4*)

CH.A CH.B

*) ONLY WHEN BOARD TYPE B2

Figure 131 Safety outputs for safety module SIB-V type 1/2, max. 2 A

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6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12

AREA 1 AREA 1 STN 1 STN 2 AREA 2 AREA 2

CH.B CH.A CH.B
CH.A

Figure 132 Safety outputs for safety module SIB-V type 3, max. 2 A

PNEUM. VALVE PNEUM. VALVE

AIR SUPPLY AIR SUPPLY
STN1 STN2

1 2

2
SAFETY RELAYS
B

B 1
A B 1 2
A
A

7% 7%
1 2 3 4 5 6 7 8 15 16
EM.
TEST INPUT STOP
CH.B
EM.
AREA 1 AREA 1 STN 1 STN 2 STOP
CH.A CH.B CH.A
7%
5 6

2 1 1 2
In1

In2

On1

On2

OUTPUT(S) OUTPUT(S)
CLAMP CLAMP
VALVE(S) VALVE(S)
STN 1 STN 2

Figure 133 Example of the fixture interlock principle with safety module SIB-V type 1

504773-01_en.fm 265
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PNEUM. VALVE PNEUM. VALVE

AIR SUPPLY AIR SUPPLY
STN1 STN2

1 2

SAFETY RELAYS
1B 2B

1A 1B 1 2 2A 2B
1A 2A

6,%
7%
1 2 3 4 5 6 7 8 9 10 11 12
EM.
STOP
CH.B
EM.
AREA 1 AREA 1 STN 1 STN 2 AREA 2 AREA 2 STOP
CH.B CH.A CH.B CH.A
CH.A
TEST INPUT TEST INPUT

7% 7% 7%

5 6 2 3 8 9 8 9

1B 2B 1 2

On1

On2
In1

In2

1A 2A
INPUT INPUT OUTPUT(S) OUTPUT(S)
ACTIVATE ACTIVATE CLAMP CLAMP
CLAMP CLAMP VALVE(S) VALVE(S)
VALVES VALVES STN 1 STN 2
STN 1 STN 2

Figure 134 Example of the fixture interlock principle with safety module SIB-V type 3

266 504773-01_en.fm
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5.9 Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

504773-01_en.fm 267
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snitt tion InterFace

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15 504 996-880 Säkerhetskort V, Typ 3 SafetyInterfaceBoard V, SIB
Type 3
17 489 947-469 Anslutningsdon, Combi- Connector, Combicon 7 pol
con
18 500 958-001 Insticksbrygga Bridge 7 pol

20 436 829-009 Jordklämma Terminal

41 502 294-880 Kabelstam Cable harness

268 504773-01_en.fm
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Interface for operator communications

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Interface for operator communications

270 504773-01_en.fm
 Control Cabinet
Interface for operator communications

5.10 No safety equipment

On installations without safety equipment the interface is replaced by an assembly
plate for operator communications. All requisite jumper settings, etc for internal
cabling included in the top cabinet are fitted on the assembly plate.
The assembly plate is fitted on the right-hand side, inside the top cabinet and can
be used as spare space for other customer specific equipment.

5.10.1 Operator communication

A connection cable with an interface to operator communication is supplied. The
interface is equipped the same irrespective of the type of positioner.
Free space on the assembly plate can be used, for example, to install customer
specific equipment.

2 4

1 Power supply (A203-TB7)

2 Jumper device emergency stop (Fitted in socket X104 on the left of the
cabinet)

3 Jumper device operating stop chain (A203-TB1)

4 Connection cabling for the Operator’s panel

Power supply
The following voltages are available on the jackable terminal A203-TB7:
• 24V DC (24V I/O)

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Interface for operator communications

5.10.2 OPERATION and CONNECTIONS

Emergency stop

1
3
Cabinet_S4Cplus_12

2
4

1 Motors on

2 Emergency stop

3 Operating mode selector

4 Running time meter

All emergency stop buttons included in the system are as standard connected in
series and directly affect the control system’s emergency stop loop.
Included on external safety equipment, available in the standard range, are:
- an emergency stop button on the operator’s panel
- an emergency stop button on the equipment cabinet for the roller door.
The "Extended emergency stop function" option gives the possibility of
supplementing equipment with components for, e.g. gate interlocking via the
emergency stop of fixtures.
Optional redundant auxiliary relays can then be easily connected for this purpose.

272 504774-01_en.fm
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Interface for operator communications

Figure 135 and Figure 136 below show the theory behind how the emergency stop
loop is used to control connected equipment.
For detailed information about the design of the emergency stop loop refer to the
"The robot’s User’s Manual"
emstop

Figure 135 Emergency stop loop

emstopoption

Figure 136 Emergency stop loop with the addition "Extended emergency stop function"

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Interface for operator communications

5.10.3 Interlocks

Operating stop loop

Figure 137 shows below the theory behind how the operating stop loop is used to
control connected equipment.
For detailed information about the design of the operating stop loop refer to the
"The robot’s User’s Manual"
runchain

Figure 137 Operating loop

The following voltages are available on the jackable terminal A203-TB1:

• Auto stop
• General stop

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Interface for operator communications

5.11 Reservdelsförteckning/Spare Parts List

Reservdelar beställs genom ABB Automation Technology Products AB. Vid
beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och
beställningsnummer enligt reservdelsförteckningen.
Rätt till ändring av specifikationer utan avisering förbehålles.
Spare parts are to be ordered from ABB Automation Technology Products AB.
Kindly indicate type of unit, serial number, denominations and ordering number
according to the spare parts list.
Rights to reserved to alter specifications without notice.

504774-01_en.fm 275
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Interface for operator communications

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41 504 979-880 Kabelstam Cable harness

276 504774-01_en.fm
 Control Cabinet
Interface for operator communications

11

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Interface for operator communications

278 504774-01_en.fm
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Technical Data

6 Technical Data
Also refer to the Product Manual for the robot

Weight 280kg (without welding power source)

380kg (with welding power source)
Additional 20kg top cabinet 820 mm
Additional 20kg pivot frame
Additional 30kg welding power source
with transformer
Dimensions (WxHxD), top cabinet 820mm in brackets
800x1570(1770)x623mm (without welding power source)
800x2010(2210)x623mm (with welding power source)
Environmental demands
Transport temperature Min –25°C
Max +42°C
Max +70°C
Operating temperature (ambient) Min +5°C
Max +45°C
Relative humidity Max 95% at constant temperature
Electrical data (incl. control cabinet):
Mains voltage 3x200 – 600V AC, +10%,-15%
Frequency 48.5 – [Link]
Fuse protection 16A slow burn (400V)
The following applies for the control cabinet with welding power source
LRB400:

Nätspänning/ Säkring (Trög) /

Mains voltage Fuse (Slow-blow) 2)
(V) (A)

200 80

220 80
1 ) 400 32 ( 35 )

440 40 ( 50 )

475 40 ( 35 )

500 32 ( 35 )

525 32 ( 35 )

600 32 ( 35 )

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Technical Data

) 400V without power source transformer.

1

) Fuses in brackets can be used if the recommended fuse is not available.

2

Rated power (without/with ext. axes) 4.5/7.8kVA without welding power

source
17.5/20.8kVA with welding power
source
Protection class IP54
IP21 welding power source LRB400

280 504868-06_en.fm
 Control Cabinet
Installation and set-up

7 Installation and set-up

This work may only be carried out by persons trained in the use of the complete
equipment and who are aware of the special risks involved with these different
parts.

7.1 Transport and unpacking

The safety instructions and other instructions should be studied carefully
before starting transport and unpacking of the safety equipment. These can
be found under a separate tab in the System manual.
• Check that the equipment is not damaged in any way.
• Report any visible transport damage immediately.

7.2 Lifting instructions

The control cabinet is fitted with lifting eyes to allow easy lifting.
Lifting of the manipulator may only:
- be carried out using equipment that corresponds with applicable lifting
standards.
- be carried out by authorised personnel.
Do not walk under a suspended load!

min 60 degrees
lifting instructions

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Installation and set-up

7.3 Mechanical installation

7.3.1 Function pack and FlexArc

The base of the control cabinet has fastening holes for secure mounting to the floor.
• NOTE! Install the control cabinet according to the instructions in
theRobot’s Product Manual.

7.4 Connections

7.4.1 Mains connection

The main connection must be carried out
by qualified personnel.
Data for the supply voltage, fuse protection,
etc. can be found in chapter “Technical
Data” på sidan 279.
Control cabinet_S4Cplus-7

Function pack
• Install the control cabinet according
to the instructions in theRobot’s
Product Manual.
• The mains voltage is connected to the
control cabinet's main power switch
as set out in the diagram.

FlexArc
In weld cells of the type FlexArc the connection cable is routed to a 63A IEC inlet,
placed on the cell wall for easy mains connection.

7.5 Check before start up

NOTE! Keep the doors to the control cabinet and top cabinet closed to prevent
dust and dirt from entering.
Before switching on the voltage check that the following has been done:
• Check that all component equipment is connected correctly.
• The main voltage is according to the identification plate on the control
cabinet.
• The programming unit is connected.
• If external safety equipment is used. Check that it is installed:
• The operating mode selector on the control cabinet's control panel is
in the
- MANUAL position .
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Installation and set-up

7.6 Start up
All requisite system software is installed on delivery.
• Switch on the main power switch on the control cabinet and the main power
switch on the welding power source if fitted. The main power switch on the
control cabinet normally controls the power supply to all component
modules in the cabinet.
Note! Some power sources supply the process control card with an external
reference voltage, which is why some parts of the control cabinet can be
voltage fed even when the main power switch is in the "OFF" position.
• The robot makes a self-test on the hardware and software. This test takes
about 1 minute.
• Wait until the message “Welcome to....” is shown on the programming
unit's display.
The system is now ready for use.

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Maintenance

8 Maintenance
The wrist strap, provided in the cabinet, must be worn when handling the
circuit
cards and other electronics in the control cabinet to prevent ESD damage.
• The control system is fully enclosed and the electronics are thereby
protected in a normal workshop environment.
In very dusty and powdery environments the cabinet should, however, be
checked regularly internally. If necessary use a vacuum cleaner.
• Clean any filters according to the instructions in the robot's Product Manual
as well as in the power source's Product Manual.
• Check that the cables/connectors are not damaged. Damaged components
must be replaced immediately.
If safety equipment is included:
• this should be tested preferably at the start of each shift.

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Maintenance

286 504868-u_en.fm
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