ABB FlexLoader Applications Manual
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ABB FlexLoader Applications Manual

Standard safety center
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ROBOTICS
Application manual
FlexLoader Standard Safety Center

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Summary of Contents for ABB FlexLoader

  • Page 1 ROBOTICS Application manual FlexLoader Standard Safety Center...
  • Page 2 Trace back information: Workspace Robots and Applications version a61 Checked in 2020-03-06 Skribenta version 5.3.033...
  • Page 3 Application manual FlexLoader Standard Safety Center R19D Document ID: 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Safety functions ....................Error messages ....................Starting from a non-powered status ..............Pluto I/O ......................Safety center response times ................Installation guide ....................Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
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  • Page 7: Overview Of This Manual

    Prerequisites Operators and maintenance, repair and installation personnel working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation, service and maintenance work. Trademarks FlexLoader is a trademark of ABB.
  • Page 8 Revision Description First edition. Updated illustrations. General update. Include Profinet update. Improved information on master/slave interfaces. Minor updates. Added section on response times. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 9: Safety

    Equipment that is part of a fully- or semi-automatic system must always be treated with care regarding safety. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed, and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

  • Page 10: Safety During Installation, Commissioning And Decommissioning

    Personnel who are involved in the installation and commissioning must have relevant training for the respective robot and corresponding safety issues. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 11: Safety During Setup, Maintenance, Service And Repair

    1.3 Safety during setup, maintenance, service and repair 1.3 Safety during setup, maintenance, service and repair Always ensure that FlexLoader Standard Safety Center cannot be started when working on the cell. The installed protection that belongs to the equipment must always remain installed during automatic operation.

  • Page 12: Limitation Of Liability

    1.4 Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the FlexLoader Standard Safety Center will not cause injury or damage even if all safety instructions are complied with.

  • Page 13: Nation And Region Specific Regulations

    To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where FlexLoader Standard Safety Center is installed. Within the EU, refer to the Machinery Directive 2006/42/EC with addendum.

  • Page 14: To Be Observed By The Supplier Of The Complete System

    1.6 To be observed by the supplier of the complete system Overview The integrator is responsible for making sure that the safety devices necessary to protect people working with FlexLoader Standard Safety Center are designed and installed correctly. When integrating FlexLoader Standard Safety Center with external devices and machines: •...
  • Page 15 1.6 To be observed by the supplier of the complete system Continued The FlexLoader Standard Safety Center used with Eden door switches does not evaluate door locking in its safety function. This has to be considered in the risk assessment.

  • Page 16: Safety Signals In The Manual

    NOTE Signal word used to indicate important facts and conditions. Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 17 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
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  • Page 19: Description Of The Product

    It is based on the ABB Pluto programmable safety controller. It handles emergency stops and protective stops in the cell and ensures safe and reliable interaction with external equipment. FlexLoader Standard Safety can be configured and covers a broad range of safety interface needs. DANGER The Pluto program is a critical part of the safety system of the cell.
  • Page 20 Typical integration example The equipment can be integrated in several different ways. Below is a typical example of how the safety center can be integrated with other equipment. The example shows the FlexLoader Standard Safety Center with all connected devices. xx1800002552 Pos.

  • Page 21: Installation

    This section describes how to install the equipment. If the cell contains further parts, safety instructions may also be found in other documentation. Configurations FlexLoader Standard Safety Center is pre-installed (optional) in FlexLoader function packages. During installation, the configuration must be changed according to project needs...
  • Page 22 In order for the external equipment in the safety function ”protective stop of all equipment” to fulfil the PLd, the equipment must fulfil all PLd requirements. Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 23 The standard network setup with its three main networks is configured as shown below. xx1800002353 • The factory network connects to both the FlexLoader Vision PC and the robot. This network is optional. • The camera network is reserved for FlexLoader Vision cameras.
  • Page 24 IP addresses that are pre-configured in the controller. ABB CI502 I/O nodes will get its name depending on the switches/knobs on the module, e.g. ci502-pn-01 if knobs are put in positions 0 (x10H) and 1 (x01H). A cold start is needed to read new name.
  • Page 25 For connecting two robot controllers or an external master PLC to the cell, see External PROFINET connections on page Note Robot option 841-1 Ethernet/IP™ cannot be combined with the FlexLoader function packages and standard cells. If Ethernet/IP™ communication is needed, the robot option 840-1 Ethernet/IP™...
  • Page 26 External PROFINET connections In some cases external PROFINET connections are needed during integration of a FlexLoader function package or standard cell. A second robot controller can be connected through PROFINET by using a PROFINET fieldbus adapter in the second controller (robot option 840-3).
  • Page 27 WAN instead of LAN2. However, this will expose all components to an external network. We recommend to avoid this system setup. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
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  • Page 29: Maintenance

    How: Inspect the entire cable rack (installation points, dirt deposits, wear) and remedy any breaks. Check all cables. Replace damaged cables. Extend cables that rub against sharp edges. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
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  • Page 31: Interface

    Most often, the connected system is the master of the safety system and FlexLoader Standard Safety Center is a slave. FlexLoader Standard Safety Center can also assume the role of the master in the safety system, either to other slaves or as a master cooperating with another master.
  • Page 32 Protective stop Protective stop is transmitted via a two-channel, potential free signal to the connected system from the safety relay of the FlexLoader Standard Safety Center. Optionally, the connected system transmits a protective stop via a two-channel , potential free signal to FlexLoader Standard Safety Center using a two channel safety device.
  • Page 33 FlexLoader Standard Safety Center acting as emergency stop button Emergency stop Protective stop The connected system transmits the master emergency stop via a two-channel, potential free signal from its safety relay to FlexLoader Standard Safety Center. xx1800000176 Pos. Description Connected system is emergency stop master FlexLoader Standard Safety Center receiving a two-channel, potential free signal The connected system is responsible for resetting the emergency stop.
  • Page 34 5.1 External safety interface to connected system Continued The connected systems are emergency stop slaves The connected system transmits the emergency stop via a two-channel , potential free signal to FlexLoader Standard Safety Center acting as an emergency stop button. xx1800002558 Continues on next page...
  • Page 35 FlexLoader Standard Safety Center is emergency stop master Connected system acting as emergency stop button Emergency stop Protective stop FlexLoader Standard Safety Center transmits the emergency stop via a two-channel, potential free signal from its safety relay to the connected system. xx1800000176 Pos.
  • Page 36 This operating mode should be avoided because there can be small residual risks in the communication between the masters. If possible, select a system where only FlexLoader Standard Safety Center is master. FlexLoader Standard Safety Center transmits emergency stop via a two-channel, potential free signal to other systems.
  • Page 37 This behavior depends on the exact emergency stop implementation in the connected master systems and must be risk assessed for every cell. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 38: Internal Safety Interface

    5.2 Internal safety interface 5.2 Internal safety interface Introduction The FlexLoader Standard Safety Center is the safety master towards all internal equipment, e.g. feeding devices, robot, safety doors and other equipment. The following interfaces are provided by FlexLoader Standard Safety Center.
  • Page 39 Risk assessment must confirm safety distances from door openings to hazard areas. The cables are connected to terminals in the FlexLoader cabinet. For more detailed information see the wiring diagram. Enable door lock If Magne locks are used, the robot typically locks the door through it's I/O system (application specific).
  • Page 40 The MotorsOn signal from the robot is transmitted via a two-channel, potential free signal from the robot contactors. The cables are connected to terminals in the FlexLoader cabinet. For more detailed information see the wiring diagram. Safety interface to FlexLoader function package...
  • Page 41 We recommend the use of the following valve: Festo MS6-SV-1/2-D-10V24P-2M8-SO-AD1 (or compatible). xx1900001048 Figure 5.1: Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
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  • Page 43: Function Description

    FlexLoader function package or standard cell, e.g. the robot, FlexLoader FP 400, a rotation unit or similar. “External” refers in a typical case to the customer’s machine tool(s) (for example a transfer machine, lathe, press or similar).
  • Page 44 The dangerous equipment can be enabled by means of the enabling device on the FlexPendant combined with the reset key switch at a door. A dedicated risk analysis must be performed prior to using this functionality. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 45: Operation

    Center emergency stop button. • Reset the emergency stop. • Open and close at least one internal FlexLoader Standard Safety Center cell door. • Reset the door status by shortly turning the reset key. Optionally, if a light curtain is present, a long light curtain reset may be needed (0.5 s) first, followed by a second reset for the whole cell.

  • Page 46: Protective Stop

    7.2 Protective stop Introduction The FlexLoader Standard Safety handles protective stop and manual operation of dangerous equipment. The protective stop mode ensures safe stop of equipment upon cell entry and prevents the equipment from being started while the cell is accessible.
  • Page 47 Restart the robot cell through routines provided by the robot program. Manual operation of dangerous equipment By default the protective stop is activated as soon as any FlexLoader Standard Safety Center door is opened. This deactivates dangerous equipment in the cell.
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  • Page 49: Decommissioning

    Before disposal of any storage equipment (anything from an SD card to a complete controller), make sure that all sensitive information has been deleted. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 50: Environmental Information

    Incineration must be carried out under controlled conditions in accordance with local regulations. Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 51 Spillage can penetrate the soil causing ground water contamination. Hazardous material The table specifies some of the materials in the FlexLoader function package and their respective use throughout the product. Dispose of the components properly to prevent health or environmental hazards.
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  • Page 53: A Technical Data

    Pluto is emergency stop master among other emergency stop masters (ManyEmergencyStopMasters) FlexLoader Standard Safety Center is always protective stop master. This means that protective stops can be reset at the FlexLoader doors. The following additional options can be specified for special needs: •...

  • Page 54: Safety Functions

    Emergency stops from the external equipment are expected to come from the emergency stop relays. The emergency stops must be reset on the external equipment. Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 55 The emergency stop to the external equipment comes from the emergency stop relays outputs. The emergency stop must be reset on the FlexLoader equipment. Emergency stop safety function If an external or internal emergency stop is made, that is if one of the signals...
  • Page 56 1 (at least 0.2 s) OutEmergencyStopInternal is set to Protective stop can then be reset according to the rules for protective stop. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 57: Error Messages

    If the two-channel requirement is not fulfilled, the associated input LED on Pluto flashes twice. Two-channel faults can be resolved by opening both channels and then closing them again. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 58: Starting From A Non-Powered Status

    Operation on page Configuration Odd number of Even number of doors/switches doors/switches Pluto as slave Pluto as master Pluto as master among other masters. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 59: Pluto I/O

    (static, option) IQ 17 DynA Generates signal DynA OutEmergencyStopExternal Emergency stop for external equipment via expansion relay Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 60 OutAutoStopInternalExternal Protective stop for both internal and ex- ternal equipment via expansion relay OutEmergencyStopInternal Emergency stop for internal equipment via expansion relay Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 61: Safety Center Response Times

    (< 20.5 ms + 5 ms + 20 ms) Typical response times for internal emergency stop • Response time: < 25.5 ms (< 20.5 ms + 5 ms + 20 ms) Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.

  • Page 62: Installation Guide

    3 Select Open with permission to configure and enter the password config123. Click OK. xx1800000422 4 Verify the checksum for the program according to the release notes. Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 63 7 The next step is to compile the program. Click Comp. xx1800000425 Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 64 For later downloading the correct password must be used to download a new program in Pluto. xx1800000428 Continues on next page Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 65 3 When downloading programs in Pluto, the execution of program operation is stopped. Therefore, click Yes to restart execution. xx1800000429 4 Perform the same sequence as at restart from unpowered status. Application manual - FlexLoader Standard Safety Center 3HAC051769-001 Revision: E © Copyright 2014-2020 ABB. All rights reserved.
  • Page 68 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2014-2020 ABB. All rights reserved. Specifications subject to change without notice.

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