Power and productivity jl II II

for a better world™ I'll\ IIII

Trace back information:
Workspace R12-2 version a11 (not checked in)
Published 2012-10-25 at 08:34:22
Skribenta version 1184
 Application manual
Electronic Position Switches
RobotWare 5.15.01

Document ID: 3HAC027709-001

Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.

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.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

© Copyright 2006-2012 ABB. All rights reserved.

ABBAB
Robotics Products
SE-721 68 Vasteras
Sweden
 Table of contents

Table of contents
Overview of this manual .................................................................................. ........... ...................... 7
Product documentation, M2004 .............................. ................................................... ...................... 9
Safety ......................................................................................................................................... ....... 11

1 Introduction 13
1.1 Overview of Electronic Position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Terminology .... ... ....... .. .. ........ ..... ... .... .... ....... .. .. ....... .. .. .... .... ... ....... .... .. ....... .. .. .. 16

2 Electronic Position Switches functions 17

2.1 Monitor Axis Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Cyclic Sync Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Software Sync Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Control Error Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Operational Safety Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 Installation 25
3.1 Hardware installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1 1/0 connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.2 1/0 signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . 28
3.1.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.4 SMB connection for additional axis .. . . . .. . .. . . .. . . ... . .. .. . . . ... .. . .. . . . .. . . . .. . . .. . . .. . ... .. . . 34
3.2 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.1 Installing required software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 Configuration 37
4.1 Create a safety user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 EPS Configuration Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Configuration for robots with non-zero calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.4 Configuration for Multi Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.5 Activating the safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6 Validate the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.7 Viewing the configuration on the FlexPendant ... ...... ......... ... .... ...... ........ ..... ..... ..... .. 60

5 Synchronization 61
5.1 Synchronization guidelines for Cyclic Sync Check .. . . . ... . .. . .. . . ... . .. . .. . . .. . . .. .. .. . . . ... .. . .. . . . 61
5.2 Synchronization guidelines for Software Sync Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6 Running in production 65
6.1 Reaction time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Recovery after safety violation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Virtual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.4 Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

7 Example application 69
7.1 Example with two work zones . . .. . . . .. . .. . . . .. . .. . . .. . . .. . ... .. . . . .. . .. . . .. . . ... . .. .. . . . . . .. . .. . . ... . .. . .. . 69

8 Safety aspects for Electronic Position Switches 73

8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2 Safety requirements... .. .... ... .... ... .. ..... .... ........ ... .. .... .... ....... ..... ...... ..... .. ...... .. ... ... 74
8.2.1 Standards conformance ..... ..... ...... ...... ..... ..... ............. .... ...... ........ ..... ...... .. 74
8.2.2 Specific safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.3 Safe design of Electronic Position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.4 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.5 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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Table of contents

Index 81

6 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 Overview of this manual

Overview of this manual

About this manual
This manual describes the Electronic Position Switches option and contains
installation descriptions of the hardware. It also describes the add-in software,
which is added to RobotStudio and used for configuration of Electronic Position
Switches.

Usage
This manual should be used during installation and configuration of Electronic
Position Switches.

Who should read this manual?

This manual is mainly intended for:
personnel that are responsible for installations and configurations of
hardware/software
personnel that make configurations of the 1/0 system
• system integrators

Prerequisites
The reader should have the required knowledge of:
mechanical installation work
• electrical installation work
• working with industrial robots
using RobotStudio
personal safety, see the safety chapter in Product manual - IRCS.

Organization of chapters
The manual is organized in the following chapters:

Chapter Contents
1Introduction This chapter gives an overview of the Electronic Position
Switches option, and describes the purpose.
2Electronic Position Descriptions of all functions included in Electronic Position
Switches functions Switches.
31nstallation Workflows for how to install hardware and software for Electronic
Position Switches.
4Configuration Workflows for how to configure Electronic Position Switches.
SSynchronization Describes some considerations for the required synchronization.
6Running in production Information that is useful after installation, such as performance
specifications, what to do if the supervision triggers and virtual
signals that can be used in a RAPID program.
?Example application Example of a typical problem that is solved with Electronic Po-
sition Switches.
8Safety aspects for Elec- Describes how Electronic Position Switches complies with rel-
tronic Position Switches evant safety standards and regulations.

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Overview of this manual

Continued

References

Reference Document ID
Operating manual - RobotStudio 3HAC032104-001
Product manual - IRC5 3HAC021313-001
Technical reference manual - RAPID Instructions, Functions 3HAC16581-1
and Data types
-
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001

Revisions

Revision Description
- First edition. Released with Electronic Position Switches.
A Installation procedure removed from this manual. Installation and replacement
information can be found in Product manual - IRC5.
Information added about test pulses on output signals.
Example application added.
Minor corrections.
B Added section about reaction time.
In the EPS Configuration Wizard, the configuration of Monitor Axis Range has
a new checkbox called Invert function, which is described.
c New chapter added, Safety aspects for Electronic Position Switches. Addi-
tions/corrections are made.
D Added section Configuration for robots with non-zero calibration position on
page 51 .
Added information to Create RAPID program for synchronization on page 61 .
Corrections following updates in the user interface in EPS Configuration Wizard
on page 39.
Added section Status LED on page 68.
Correction in section Virtual signals on page 67. The virtual signals cannot be
used in a RAPID program.
Added information to section Installing required software on page 35, that EPS
Configuration Wizard is pre-installed in RobotStudio from RobotWare 5.11.
E Updated section Installing required software on page 35: the EPS Configuration
Wizard is installed with RobotStudio.
Software Sync Check is introduced as alternative to Cyclic Sync Check.
Added section Viewing the configuration on the FlexPendant on page 60.
Updated safety signal graphics for the levels Danger and Warning.
F The grant Execute program is added in section Create a safety user on page 37.
G Added section Supported additional axes on page 14.
New grant described in section Granting right to perform software synchroniz-
ation on page 38.
H Updated section Power supply on page 32 with information regarding common
ground potential.
J ongoing Updated section SMB connection for additional axis on page 34 with information
regarding the SMB connection.

8 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 Product documentation, M2004

Product documentation, M2004

Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing
is based on the type of information in the documents, regardless of whether the
products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
Technical reference manual - RAPID Instructions, Functions and Data types :
Description and syntax for all RAPID instructions, functions, and data types.
Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.

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Product documentation, M2004

Continued

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, 1/0 boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
• Operating manual - Emergency safety information
• Operating manual - General safety information
• Operating manual - Getting started, IRC5 and RobotStudio
• Operating manual - Introduction to RAPID
• Operating manual - IRC5 with FlexPendant
• Operating manual - RobotStudio
• Operating manual - Trouble shooting IRC5, for the controller and manipulator.

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© Copyright 2006-2012 ABB. All rights reserved.
 Safety

Safety
Safety of personnel
When working inside the robot controller it is necessary to be aware of
voltage-related risks.
A danger of high voltage is associated with the following parts:
• Units inside the controller, for example 1/0 units, can be supplied with power
from an external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the
machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing
mechanical and electrical installation work.

Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety regulations described in Product manual - IRCS.

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This page is intentionally left blank
 1 Introduction
1.1 Overview of Electronic Position Switches

1 Introduction
1.1 Overview of Electronic Position Switches

Purpose
Electronic Position Switches is a safety controller in the robot system. The purpose
of the safety controller is to ensure a high safety level in the robot system using
electronic position switches and safe digital output signals.
The output signals can be connected to, for instance, a safety PLC that will generate
stops in the robot system by opening the safety chain. The safety controller also
sends status signals to the main computer, that is the standard IRCS robot
controller.
Some examples of applications:
• Monitoring of all robot axes.
• Replacing mechanical position switches.

&. WARNING

The safety controller has passive monitoring, i.e. it does not stop the robot. If an
axis is outside its configured range, an output signal goes low. It is the
responsibility of the installation personnel to connect the output signals in such
a way that the robot is stopped if there is a risk of a dangerous situation.

What is included
The following is included with the option Electronic Position Switches [810-1]:
• Safety controller (3HAC026271-001)
• 14 pole plug contact for 1/0 connections.
The option Electronic Position Switches gives you access to EPS Configuration
Wizard functionality in RobotStudio.
With EPS Configuration Wizard you can:
• set up monitoring of all robot axes
• quickly modify the monitoring settings.

Basic approach
This is the general approach for setting up Electronic Position Switches. For more
detailed instructions of how this is done, see chapters Installation and Configuration.
1 Connect 1/0 connections to sync switch and safety PLC, or similar.
2 Create a safety user in the User Authorization System, UAS (using
RobotStudio).
3 Configure the settings for Electronic Position Switches functions via the EPS
Configuration Wizard and restart the controller.
4 Log on as safety user and set the PIN code on the FlexPendant. Restart the
controller.

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1 Introduction
1.1 Overview of Electronic Position Switches

Continued

5 Synchronize the safety controller, using a sync switch or software

synchronization.
Now the monitoring functions are activated.
6 Validate the configuration.

Limitations
Electronic Position Switches can only monitor one additional axis. This axis must
be connected to SMB link 1.
Continuously rotating axes cannot be monitored.
Drive units cannot be shared, for instance between positioner axes.
Electronic Position Switches uses only passive monitoring, that sets output signals
but does not stop the robot.

Supported robots
The following robot families are supported by Electronic Position Switches:
• IRB140
• IRB 260
• IRB 660
• IRB1600
• IRB 2400
• IRB 2600
• IRB 4400
• IRB 4600
• IRB 5400
• IRB 6620
• IRB6620LX
• IRB 6640
• IRB 6660
• IRB 6650S
• IRB 7600
Other robot models are not supported.
Electronic Position Switches cannot be used for parallel robots, such as IRB 360.

Supported additional axes

Basically the option Elect.ronic Position Switches only supports ABB track motion
units. Non ABB track motion units and non ABB positioners may be supported by
Electronic Position Switches if the customer configures the appropriate parameters.
Electronic Position Switches only supports additional axes that are single axis
mechanical units. For example, two axes positioners cannot be supported.
Further, there are always the following upper and lower work area limitations:
• Track unit length (arm side) max ± 100 m
• Rotating axis (arm side) max ± 25 700 degrees or± 448 radians
On the motor side there is also a limitation of ± 1O OOO revolutions.

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 1 Introduction
1.1 Overview of Electronic Position Switches

Continued

Requirements
Robust monitoring function in Electronic Position Switches requires correct settings
of payload and additional axes, since this will affect the calculated accepted servo
lag. Please also note that external forces applied on the manipulator can cause a
negative influence on the monitoring functions, since the servo lag might differ
from the calculated values, due to such external forces .

• DANGER

An Electronic Position Switches configuration must always be validated to verify

that the desired safety is achieved. If no validation is performed, or the validation
is inadequate, the configuration cannot be relied on for personal safety.

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1 Introduction
1.2 Terminology

1.2 Terminology

About these terms

Some words have a specific meaning when used in this manual. It is important to
understand what is meant by these words. This manual's definitions of these words
are listed below.

Term list

Term Definition
Monitoring Passive monitoring with signaling function only.
Occupationally safe Safe for a person to be in an area.
Operationally safe Safe for the machinery but not safe for persons to enter the
area.
Safe input Dual monitored digital input.
Safe output Dual monitored digital output.
Safety controller A safety board used with IRC5. Can be an Electronic Position
Switch safety controller or a SafeMove safety controller.
Antivalent signal Same as complementary signal. The logical value of one
channel is the complement of the other in a dual channel signal.
Equivalent signal The logical value of one channel is equivalent to the other in
a dual channel.

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 2 Electronic Position Switches functions
2.1 Monitor Axis Range

2 Electronic Position Switches functions

2.1 Monitor Axis Range

Monitor Axis Range

Monitor Axis Range is a monitoring function that determines if all axes are within
the defined ranges. Safe digital output signals are used to indicate when all axes
are within their defined ranges.

D Note

Monitor Axis Range can only safely determine that the monitored axes are within
the defined ranges (i.e. when the output signal is high). It is not safe to assume
that an axis is outside the defined range when the signal is low.

Monitoring functionality
The positions of the axes can be monitored as follows :
• Up to five safe digital output signals can be defined.
• For each safe digital output signal, a combination of up to seven axis ranges
can be defined.
If an axis is outside its defined range, a safe digital output signal goes low. Each
set of axes can be allocated an output signal.

Borderline positions
In very rare cases an error message (elog 20473) might be presented if the robot
is stopped for a longer time (> 40 min) in a position exactly on the border of the
defined range due to internal design.

Settings
The following settings need to be configured for Monitor Axis Range:
• Axis ranges (degrees or mm) for each axis.
• Assignment of safe digital output for each set of axis ranges.
• Invert axis for each axis.
• Allow inside for each set of axis ranges.

Limitations
Continuously rotating additional axes cannot be monitored. If an additional axis is
continuously rotating, it must not be configured for monitoring.
If you have a continuously rotating robot axis (using independent axis for axis 4
or 6) monitoring is not used for that axis. Other robot axes can still be monitored,
but the independent axis must be specified in the configuration (see Select
mechanical unit on page 40).

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2 Electronic Position Switches functions
2.1 Monitor Axis Range

Continued

Example of ranges
This example shows a robot with defined axis ranges for axes 2 and 3 in three
different positions. The function Monitor Axis Range monitors that axis 2 is within
range x2 and that axis 3 is within range x3.
In positions A and B, all monitored axes are within the defined ranges. In position
C, axis 3 is not within the defined range.
x3
x2

A B c
xx0600003331

x2 Defined axis position range for axis 2.

x3 Defined axis position range for axis 3.
A ~ ot position A. Both axis 2 and axis 3 are within the defined ranges.
- -
B Robot position B. Both axis 2 and axis 3 are within the defined ranges.
- - -
c Robot position C. Axis 2 is within the defined range but axis 3 is not within its
defined range.

In this example, if range x2 and x3 are defined for the same signal, this signal will
go low if any of the axes is outside its defined range.
Note! The ranges define axis angles, not the position of the TCP. In robot position
C, the TCP is still within what seems to be a safe range, but axis 3 is outside its
defined range.

Continues on next page

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 2 Electronic Position Switches functions
2.1 Monitor Axis Range

Continued

Example of usage
Define two ranges for axis 1 and let a safety PLC decide when the axis must be
inside range A and when it must be inside range B.

xx0700000144

A Range for axis 1 defined for safe output signal 1.

--t---

B Range for axis 1 defined for safe output signal 2.

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© Copyright 2006-2012 ABB. All rights reserved.
2 Electronic Position Switches functions
2.2 Cyclic Sync Check

2.2 Cyclic Sync Check

Cyclic Sync Check

Cyclic Sync Check is a function that makes sure that the robot calibration is correct
by using a physical switch.

Functionality
The robot must move to a safe sync position to ensure that the safety controller
and the robot controller are synchronized. The safe sync position is defined during
configuration and stored in the safety controller.
With a defined interval (sync cycle time), the robot must move to the safe sync
position and activate a switch. If the sync check is not performed within the sync
cycle time, all output signals will go low (which should stop the robot if implemented
correctly). A warning is shown on the FlexPendant a pre-defined time (pre-warning
time) before the sync cycle time has passed.
When the switch is activated, the safety controller assumes that the robot revolution
counters are correct. It also calculates the arm position from the motor positions,
the gear ratio, and its internal revolution counter. If the position mat ches the stored
sync position within half a motor revolution, then the synchronization is assumed
to be correct.
If the synchronization is correct, the safety controller then sends elog 20452 to the
robot controller, telling that the safety controller is synchronized to its mechanical
units, and continues with its regular operation.

Settings
The following settings need to be configured for Cyclic Sync Check:
• Sync cycle time, 12-720 hours.
• Pre-warning time, 1-11 hours.
• Angles and positions of robot (and additional axes) at sync position.
How to define these settings is described in Set sync position on page 47.

Virtual output signals from main computer

A virtual output signal is set when the prewarning time has expired. Another virtual
signal will correspond to t he sync status. See also .

Limitations
• The safe sync position must be within reach for the robot. It must not be a
singularity, that is all six axis must have unique positions.

Related information
Synchronization guidelines for Cyclic Sync Check on page 61 .

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© Copyright 2006-2012 ABB. All rights reserved.
 2 Electronic Position Switches functions
2.3 Software Sync Check

2.3 Software Sync Check

Software Sync Check

Software Sync Check is a function that makes sure that the robot calibration is
correct. If wrong robot calibration easily can be detected by the application, then
it is generally possible to execute the synchronization check by software. In that
case it is done when required, not cyclically.

Functionality
Software synchronization is performed by running the service routine
SoftwareSync. How to run the service routine is described in section Use service
routine to perform synchronization on page 63.
If the safety controller has not been synchronized before, and the synchronization
attempt was unsuccessful, the user has to check and confirm on the FlexPendant
that both the robot controller and the safety controller have the same opinion about
robot axes positions.

Settings
The following settings need to be configured for Software Sync Check:
• Angles and positions of robot (and additional axes) at sync position.
How to define these settings is described in Set sync position on page 47.

Virtual output signals from main computer

A virtual output signal corresponds to the sync status. See Virtual signals on
page 67.

Limitations
Software Sync Check is only available for EPS board 3HAC026271-001 revision
06 or later.

Related information
Synchronization guidelines for Software Sync Check on page 63.

3HAC027709-001 Revision: J ongoing 21

© Copyright 2006-201 2 ABB. All rights reserved.
2 Electronic Position Switches functions
2.4 Control Error Supervision

2.4 Control Error Supervision

Control Error Supervision

Control Error Supervision is a function that monitors the difference between the
reference value and the measured value of the motor position of each axis. Control
Error Supervision is required to ensure the accuracy in the monitoring functions.

Supervision functionality
The control error (servo lag) is the absolute value of the difference between the
reference value and the measured value of the motor position of each axis.
Control Error Supervision is activated automatically after the safety controller has
been synchronized with the robot position.
When Control Error Supervision trips the following happens:
• All output signals go low.
• An elog message (20454) is sent to the robot controller.
• A new synchronization is required.

Illustration of control error

Control error
Motion path

_\ !
- _
/
-e -
-·-\
Actual Reference
position position
e n0700000723

Function activation
Control Error Supervision is always active. It can only be relaxed by Operational
Safety Range.

Dependencies to other functions

If Operational Safety Range is active, then Control Error Supervision is relaxed
according to user definitions.

Settings
Control Error Supervision settings are only required for additional axes.
For additional axes, the following settings need to be configured:
• Servo Lag
• Servo Delay Factor
How to define these settings is described in Configure additional axis on page 41.

Related information
Operational Safety Range on page 23.

22 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 2 Electronic Position Switches functions
2.5 Operational Safety Range

2.5 Operational Safety Range

Operational Safety Range

Operational Safety Range relaxes the monitoring of the servo lag if ALL configured
axes are within a defined axis range.

Functionality
Operational Safety Range is a special definition of an axis range that relaxes the
Control Error Supervision (servo lag) to a higher value if ALL configured axes are
within (inclusive) the defined axis range. It can be used, for instance, in machine
tending, when the servo loop gain is reduced (soft servo) or during Force Control.
It is also useful when external forces are applied to the robot.
If the robot is within the defined range, then the safety level is considered to be
operationally safe rather than occupationally safe. That means it is not safe for
personnel to be in the range defined for Operational Safety Range.
To activate the relaxed control error, all of the following conditions must be true:
• The reference values for ALL configured axes must be within the range
defined by the Operational Safety Range function.
• The measured values for ALL configured axes must be within the range
defined by the Operational Safety Range function.
The function is automatically activated after the safety controller has been
synchronized with the robot position. No dynamic activation is possible.
Up to 7 axes can be monitored simultaneously.

Settings
The following settings need to be configured for Operational Safety Range:
• Axis range definition for each axis, physical position in degrees or mm on
arm side.
• Permissible control error for each axis, in degrees or mm on arm side.
The definition of axis range consists of:
• Minimum axis limit (degrees or mm).
• Maximum axis limit (degrees or mm).
How to define these settings is described in Configure the Operational Safety
Range on page 47.

Related information
Control Error Supervision on page 22.

Continues on next page

3HAC027709-001 Revision: J ongoing 23
© Copyright 2006-201 2 ABB. All rights reserved.
2 Electronic Position Switches functions
2.5 Operational Safety Range

Continued

Examples
This example shows a robot with defined axis ranges for axes 2 and 3. The function
Operational Safety Range monitors if axis 2 is within the range x2 and if axis 3 is
within the range x3. As long as the measured values and the reference values for
both axes are within these ranges, the Control Error Supervision is relaxed.

x3

xx0600003319

24 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 3 Installation
3.1 .1 1/ 0 connector data

3 Installation
3.1 Hardware installation

3.1.1 1/0 connector data

Location

xx0600003209

A 1/0 Connector on the safety controller

B Plug contact
c Power supply
D 5 safe outputs (10 signals)
E Sync switch (dual signal)

Continues on next page

3HAC027709-001 Revision: J ongoing 25
© Copyright 2006-2012 ABB. All rights reserved.
3 Installation
3.1.1 1/0 connector data

Continued

1/0 connector pin descriptions

Power input 24V

Power input OV
MAR signal 1A
MAR signal 1 B
MAR signal 2A
MAR signal 2B
MAR signal 3A
MAR signal 3B
MAR signal 4A
MAR signal 4B
MAR signal 5A
MAR signal 5B
Sync switch input signal 1A
14 Sync switch input signal 1 B
en0600003222

Pin Signal Description

1 Power input 24 V Plus pole for power to the 1/0 connector.
2 Power input O V Minus pole for power to the 1/0 connector.
3 MAR signal 1A Monitored high side output signal for Monitor Axis Range. The
signals are configured in the EPS Configuration Wizard.
I Switches on or off 24 Volts supplied by the power input (pin 1 and
2).
4 MAR signal 1 B "
5 MAR signal 2A "
6 MAR signal 28 "
7 MAR signal 3A "
8 MAR signal 38 "
9 MAR signal 4A "
10 MAR signal 48 "
11 MAR signal 5A "
12 MAR signal 58 "
13 Sync switch input Input signal for synchronization check.
signal 1A A synchronization pulse is defined by this signal connected to
ground (0 V).
I When there is no synchronization pulse, this signal should be
open or connected to 24 V.
14 Sync switch input Input signal for synchronization check.
signal 18 A synchronization pulse is defined by this signal connected to 24
v.
When there is no synchronization pulse, this signal should be
I open or connected to ground (0 V).

Voltage and current data

Description Min value Max value

Voltage for 1/0 power supply 21.6 V 26.4 V
Voltage for low value on digital input 1-3 v +2V

Continues on next page

26 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 3 Installation
3.1.1 1/ 0 connector data

Continued

Description Min value Max value

Voltage for high value on digital input +21 V +27V
Max output current by one digital output - 0.8A
Sum of output current by all digital outputs - 2.2 A

Signal redundancy
All output signals have redundancy as a safety measure, i.e. output signal 1A and
output signal 1B should always be identical. If they differ for more than
approximately 100 ms, there is an internal error. Always handle this error by
stopping all mechanical units.
The input signal used for sync check uses redundancy where input signal 1A is
the inverted signal of input signal 1B. Here you have the choice of only using input
signal 1B, but this must be defined in the EPS Configuration Wizard.

3HAC027709-001 Revision: J ongoing 27

© Copyright 2006-201 2 ABB. All rights reserved.
3 Installation
3.1.2 1/0 signals

3.1.2 1/0 signals

Using the input signal

The safety controller requires an input signal for Cyclic Sync Check. Connect a
signal from a sync switch. When the robot is in its sync position, pin 14 should be
set high and pin 13 should be set low. If dual channel wiring is not used, connect
only pin 14.
Principle for sync switch connected to the safety controller using dual input signal:

Safety
contro ller

pl n13-01 IA~--+--- o--+----

pin14-DI 181 - - - - + _ . - "-1- - -
Sync switch + -

PSU 24 V

en0600003304

Principle for sync switch connected to the safety controller using single input signal:
Safety
contro lle r

Sync switch
en0600003305

Additional axis
When synchronizing an additional axis and a robot, use a separate sync switch
for the additional axis and connect it in series with the sync switch for the robot.

Safety
cont roller

pin 13-01 1A~ - - - I - - - o--1- - ---1--r <-1- - --+

pin14-DI 181--- --1--r o--1----+-- "--!- - -
Sync switch Sync switch + -
for robot for additional
axis

PSU 24V

en0600003312

Exception: If the additional axis is a track motion or a robot-held tool, it can use
the same sync switch as the robot. These types of additional axes can be treated
as a 7th robot axis. Note that this makes it more complicated to find a non-singularity
sync check position.

Continues on next page

28 3HAC027709-001 Revision: J ongoing
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 3 Installation
3.1.2 1/0 signals

Continued

Using the output signals

The safety controller has 5 dual output signals that indicate if all axes are inside
the defined range. When performing the installation, it is the responsibility of the
installation personnel to make sure that these signals will stop the robot if an axis
goes out of its allowed range. Connect the output signals to a PLC, or similar
equipment, that can stop the robot when a signal goes low.
The safety controller works with redundancy (dual processors, dual output signals,
etc.). Safe robot behavior (inside defined range) is indicated by high value on the
output signal, so that a power failure will be interpreted as unsafe and stop the
robot.
Make sure that the output signals from the safety controller are connected in such
a way that the redundancy is preserved (if one of the dual signals goes from 24 V
to O V, the system should stop). Also make sure that a low signal always represents
the safe state that stops the robot, so that a power failure on the PLC also stops
the robot.
What the different output signals indicate is defined in the EPS Configuration
Wizard, see EPS Configuration Wizard on page 39.

Test pulses on output signals

Test pulses during start-up

At the beginning of each system start-up there are test pulses on the outputs
present. This must be considered at installation and commissioning so that it is
not interpreted as an axis being outside its defined range.

Test pulses during operation

Due to safety reasons there are test pulses on the output signals during operation.
The pulses have a maximum length of 2 ms and are only present when the outputs
are high. This must be considered at installation and commissioning so that it is
not interpreted as an axis being outside its defined range. Make sure the PLC or
safety relay does not react on pulses shorter than 2 ms.

Max inductive load

The inductive load on the outputs must be less than 200 mH.

Continues on next page

3HAC027709-001 Revision: J ongoing 29
© Copyright 2006-2012 ABB. All rights reserved.
3 Installation
3.1.2 1/0 signals

Continued

Principle for connecting signals to PLC

PSU24V
+
~
- - - - -
IRCS I
-
I PLC
I
I
I
Powellnpull4\I
- 1 I I .,.....
I <Power input l4V
Povm l11put fN
I Po.-iopot W
MA.Rl A.
MAR1B i' 01 1,
OI J8
I MAR2A ) Ol >A
MAH2!!
<""'
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MAR JA
MAR3B
<Ol lB
~ °'"
MA11 4A
I MAR • B
MAR .SA °'"
OI SA
(
MAR58 ...) OI S8
I OI IA

~
01 1B _ 1
I 4 I
I I
I- - - - - - -

Sync swit ch
I
en0600003223

Using a safety relay

An output signal from the safety controller can be connected to a safety relay which
can stop the robot immediately. This can be implemented by letting the safety relay
open the circuit for, for example, the general stop signal 1 and 2 on the panel board
of the IRC5 controller.

I IRCS Safety I
controller
MAR l A
I
Relay input
MAR 18
I

I
I
Safety relay
Panel I
board I
G~ner3I stop 1
24 V
-1-
~ner;111 stop 2 I 1
ov I
L..... - - -

en0600003306

Continues on next page

30 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 3 Installation
3.1.2 1/0 signals

Continued

Connect to Auto Stop on the panel board

A signal from a safety relay or a PLC can be connected to the Auto Stop signal of
the panel board in the IRCS controller. If the Auto Stop circuit is open, the robot
cannot move in auto mode. However, it is still possible to move the robot in manual
mode.

RCS I
Safety
contro ller
I II
I
I
Panel board (A21) Safety relay
I
Contact XS I
XS.1 1 (AS1+)
J_
X5.12(24V) I
XS.3(AS2·
XS. 1 (OV) I

- - -'
en0600003336

Connect to General Stop on the panel board

A signal from a safety relay or a PLC can be connected to the General Stop signal
of the panel board in the IRCS controller. If the General Stop circuit is open, the
robot cannot move either in auto or manual mode.
Note that when the General Stop circuit is open, there is no way of jogging the
robot back to the defined range. Therefore, using the General Stop signal requires
an additional switch to close the circuit while jogging the robot back inside the
defined range. For safety reasons, the switch used to override the relay needs to
be of safety level category 3 or higher according to EN954-1 (safety level is
dependant of the required safety level for the installation). Use, for example, a
dead man's handle.
Dead man's handle

- - - - -
RCS I
Safety
cont roller
I I I
I
I
Panel board (A21) Safety relay
I
Contact X5
I
XS.10(GS1+ ill-
XS.12 (24 V) I
X5.2 (GS2-1-
XS.1 IOVJ I

e n0600003337

3HAC027709-001 Revision : J ongoing 31

© Copyright 2006-2012 ABB. All rights reserved.
3 Installation
3.1 .3 Power supply

3.1.3 Power supply

Use IRC5 ground or isolate the 1/0

The safety controller requires one system power supply and one 1/0 power supply.
These two power supplies must have a common ground potential .
The 1/0s of the safety PLC must either have the same ground potential as the safety
controller {i.e. as the IRC5 cabinet), or the 1/0s of the safety PLC must be
galvanically isolated from the safety controller. This can be achieved in different
ways as seen in the examples below.

Example with common ground

In this example the 1/0s of the safety controller, the sync switch, and the safety
PLC has a common ground potential. The ground of the 1/0 power supply is
connected to the ground of the system power supply {i.e. the ground of the IRC5
power supply).
This setup is usable up to a distance of 30 meters between the IRC5 cabinet and
the safety PLC.

l------------------------------------------------------------1 I
I
I
I
I

xx1200000201

For a single cabinet IRC5 controller, the 1/0 power supply can be an internal power
supply located in the IRC5 cabinet. For a dual cabinet IRC5 controller, an external
power supply needs to be used.

Continues on next page

32 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 3 Installation
3.1.3 Power supply

Continued

Example with isolated 1/0

In this example the 1/0 connector of the safety controller is isolated from the safety
PLC with optocouplers. The ground of the safety controller (i.e. the ground of the
IRC5 power supply) is isolated from the ground of the safety PLC
This setup is usable up to a distance of 30 meters between the IRC5 cabinet and
the safety PLC.

-------------------~ I

xx1200000202

Example with safety bus

A solution with a safety bus will automatically solve the problem of galvanic isolation
from the PLC. It will also allow the distance between the IRC5 and PLC to be greater
than 30 meters. The maximum distance for this solution depends on the safety
bus used by the PLC.

IRCS Safety PLC

Sofety 1/0
Safety Bus

External ground

Isolated
Sync switch

e n0600003226

3HAC027709-001 Revision: J ongoing 33

© Copyright 2006-201 2 ABB. All rights reserved.
3 Installation
3.1 .4 SMB connection for additional axis

3.1.4 SMB connection for additional axis

About SMB connections

For Electronic Position Switches, you can only use SMB link 1. This means that
you can only connect one additional axis. The additional axis must be connected
to the robot SMB.

Connect additional axis directly to the robot

Connect the SMB cable from the additional axis to the SMB connection on the
robot. By connecting the additional axis here, it will be read as axis 7 on the SMB
cable from the robot to the safety controller.

xx0600003366

A SMB connection on robot base, where the additional axis can be connected as
the 7th axis in SMB link 1.

34 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 3 Installation
3.2.1 Installing required software

3.2 Software installation

3.2.1 Installing required software

H Note

RobotStudio must be of the same version or later than the RobotWare used.

Install RobotStudio
The EPS Configuration Wizard is installed with RobotStudio. Install RobotStudio
as described in Operating manual - Getting started, IRC5 and RobotStudio.
RobotStudio can be installed with the options Minimal or Full, and the EPS
Configuration Wizard is installed with either of these installation options. The EPS
Configuration Wizard is available in the Online tab of RobotStudio.

Create a robot system

Create a robot system as described in Operating manual - Getting started, IRC5
and RobotStudio. Use a drive module key that gives access to Electronic Position
Switches and select the option 810-1 Electronic Position Switches.

Configure IRCS
Configure the robot system (coordinate systems, tools, work objects, robot cell
layout, etc.) before configuring Electronic Position Switches.

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© Copyright 2006-201 2 ABB. All rights reserved.
This page is intentionally left blank
 4 Configuration
4.1 Create a safety user

4 Configuration
4.1 Create a safety user

Why do you need a safety user

Configuring Electronic Position Switches is normally done initially and then never
changed (until the robot is used for a different purpose). It is vital that the safety
configuration is not changed by unauthorized personnel. It is therefore
recommended to have specific safety users who are granted the right to configure
Electronic Position Switches.

Prerequisites
You must have created a robot system with the option 810-1 Electronic Position
Switches. How to create a system is described in Operating manual - RobotStudio.

How to create a safety user

Action
1 Request write access from RobotStudio:
In the Online browser, right-click on the controller and select Request Write Access.
If in manual mode, confirm the write access on the FlexPendant.

2 Start UAS Administrative Tool:

In the Online browser, right-click on the controller and select Authenticate and then
Edit User Accounts.
3 Select the tab Groups.
4 Click Add and type a name for the group, e.g. "Safety".
5
.
Select the group you have created and select the check boxes for the controller grants:
Execute program
. Safety Controller configuration
. Write access to controller disks
The group may have more grants, but these are the minimum required.
6 Select the tab Users.
7 Click Add and type a name for the user, e.g. "SafetyUser", and a password for the
user.
8 Select the user you have created and check the group you previously created, e.g.
Safety.
The user may belong to more groups.
9 Click OK.
10 Restart the controller.

Q Tip
Create different user groups as described in Operating manual - RobotStudio,
section Managing the user authorization system. Make sure that one administrator
has the grant Manage UAS settings and that the regular users (operators, Default
user, etc.) do not have the grants Safety Controller configuration, Write access
to controller or Manage UAS settings.

Continues on next page

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© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.1 Create a safety user

Continued

Granting right to perform software synchronization

There must always be a safety user with the right to everything that has to do with
the safety controller. The safety user can always perform a software
synchronization. If you want someone else to be allowed to perform a software
synchronization, this grant can be given to them.

Action
1 Request write access, open the LIAS Administrative tool and select tab Groups as
described in How to create a safety user on page 37.

2 Select the group that should have the grant (for example Operator).
3 Select Application grants in the drop-down box.
4 Select the check box for SafeMove/EPS software sync service routine.
5 Click OK.

38 3HAC027709-001 Revision : J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

4.2 EPS Configuration Wizard

What is the EPS Configuration Wizard

In the EPS Configuration Wizard you configure the ranges and tolerances used by
the functions of Electronic Position Switches.

Prerequisites
Only a safety user is allowed to download a configuration. A safety user must be
created before configuring Electronic Position Switches (see Create a safety user
on page37) .

Start the EPS Configuration Wizard

Action
1 In RobotStudio's Online browser, right click on the controller and select Authenticate
and then Login as Different User.
2 Select the safety user, e.g. SafetyUser. Type the password and click Login.
3 Select the controller you wish to configure. In the Online browser, right click on the
controller and select Safety Configuration and then EPS Wizard.
In the menu Tools, select EPS Configuration Wizard.
4 Click Next.

Select drive module

Select if you are configuring a single robot system or a MultiMove system.
If you configure a MultiMove system you must select which drive module you want
to configure. The configuration procedure must be repeated for each drive module.
For information about configuration of a MultiMove system, see Configuration for
MultiMove on page 54.
EP'i W1zard ir

8oloctod COM'Olot
The EPS .. be ccnfi!µecl lo lhe coroolet "'ed bdo,, Pie.,. Idec< !he G<Ve
"""" wit, lheEPS '""4lod and.-, I !he RW °"""" Soll SOM>• ....d

Controller name IPAdd,ess

SEVST-W-0001562 12100 1

Dnvemodul

en060000321 O

Click on Next.

Continues on next page

3HAC027709-001 Revision: J ongoing 39
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

Select configuration format

In the EPS Wizard you need to select the configuration format. Version 1.1.0 is the
standard format and the recommended selection, which also appears as a default
setting in the dialog box. In some rare cases, for example when you receive a new
EPS unit as a replacement of an old unit that is supporting the version 1.0.0 format,
select the version 1.0.0.

Select mechanical unit

Check the mechanical unit you want to configure.
If you want to configure a robot and an additional axis, select both. There is a
maximum of 7 axes per drive module, so if you configure a robot you cannot
configure more than one additional axis for that drive module.
If one axis is used as an independent axis, there can be no monitoring of that axis.
Under Independent Axis, you have the following choices regarding the option
Independent Axes (610-1]:
• None: Monitoring possible on all axes, but you cannot use the option
Independent Axes.
• Axis_4: Monitoring is possible on axes 1-3, but not on axes 4-6. You can
now use the option Independent Axes for axis 4 and/or axis 6.
• Axis_6: Monitoring is possible on axes 1-5, but not on axis 6. You can now
use the option Independent Axes for axis 6, but not for axis 4.
It is possible to open an existing configuration and make modifications to it. To get
the current configuration from the controller, click on Get from controller. To get
a configuration that is previously saved to file, click on Load from file.
P<;Witard I
8 e I ect m e chanical unit

-created"""lhe moch.ncal inll•l al

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the~-.. 1o«1 .....~

Noma l>'Pe Axes Independent A>Js

rv FIOB_l TcpFlobot !None .:l

P M7 S,ngleA<Js

Lood hcn lio

en060000321 1

Click on Next.

Continues on next page

40 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

Continued

Configure additional axis

If an additional axis was checked in the previous step, specify configuration
parameters for the additional axis (many of them are the same as some system
parameters defined in the topic Motion):
• Logical Axis - see system parameter Logical Axis in type Joint.
• Servo Lag - calculated lag (in radians on motor side) for the additional axis.
• Servo Delay - calculated delay factor (number of 4 ms units) when moving
the additional axis.
• Motor Commutation - see system parameter Commutator Offset in type
Motor Calibration.
• Link - see system parameter Measurement Link in type Measurement
Channel.
• Node - see system parameter Measurement Node in type Measurement
Channel.
• Board Position - see system parameter Board Position in type Measurement
Channel.
• Upper Limit - upper limit of the axis (in mm or degrees on arm side, depending
on if Rotating Move is checked). See system parameter Upper Joint Bound
in type Arm, but notice that Upper Joint Bound is specified in radians on
motor side.
• Lower Limit - lower limit of the axis (in mm or degrees on arm side, depending
on if Rotating Move is checked). See system parameter Lower Joint Bound
in type Arm, but notice that Lower Joint Bound is specified in radians on
motor side.
• Transmission Joint - see system parameter Transmission Gear Ratio in type
Transmission.
• Rotating Move - should be checked for rotational additional axis and not
checked for linear additional axis.

c:orr9,11«ion
L_.iA,,o

S<M>LAo(ltdl

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r3,J~~
~
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t ..... l.lM
~
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n

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~

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en0600003212

Continues on next page

3HAC027709-001 Revision: J ongoing 41
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

Click on OK.

II Note

Accurate values for the additional axis are important to avoid problems with too
large servo lag.

Configure motor calibration offsets

The first time you configure a new robot you must provide the motor calibration
offsets. These values are required to achieve a high precision in the monitoring of
the axes positions.
The calibration offset parameters are found in the system parameter Calibration
Offset in type Motor Calibration, topic Motion.
To set the motor calibration values, check the box Enable Calibration Offset
Configuration and then press the button Get From Controller or enter the values.
If the motor calibration values have already been set and downloaded to the
controller, leave Enable Calibration Offset Configuration unchecked and continue.
S Wizard _ f
Mo1orCa libraMn Oheb
~ M°"' c.lb•,onOftMU fr, the . - . . . 1 - r i . c.lb-.
'*
offset, won1 be dowr*J.oded to controlet I.lien EntJbled cheeked

p- -c.b..,onO"""-C<d""""" loadfrc,nfle

G" F"""Cono.-
ROB_!
_,
Calb-.on Offcec I•12G1SO :±1
A>a 2
t.albabon Offret ls 12S<n :±1
Ala l
l,33'2G1 :fl

-·
CalbaibanOffrtt

c.bahonOffrll lrn1G<O :±1

en060000321 3

Click on Next.

II Note

Observe that the motor calibration values need to be set both for the robot
controller and for Electronic Position Switches. Therefore this dialog must be
filled in even if the calibration offsets already are set in the robot controller. Every
time the calibration valu es are changed in the robot controller they also need to
be changed in the EPS Configuration Wizard. Also remember to download the
calibration file as described in EPS Configuration Wizard on page 39.

Continues on next page

42 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

Continued

Configure the Monitor Axis Range

You can define up to five different safe output signals. For each signal you can
define a range for each axis. Select output signal to configure by clicking on the
corresponding tab.
For each axis where you want to define an axis range, check the box Enable and
set the range by dragging the markers along the slide bar. The defined range is
marked green on the scale.
By checking the box Invert for an axis the range between the markers is now
outside the defined range, shown as red on the scale.
The output signal is high when all axes are within the defined range, and low when
one (or more) axis is outside.

Monilor Axia Range~

eor,;,,.,o lhe Morilo,.,. Ronoo (MARI lot the.--..,;,
°"""'sq,,121 °"""'sq,,,13) °"""'sq,,1, ) °"""'s.,,,.sl
r,...... """""
AOB_l
Am 1 ldoOI
I - t=:~J115--t F7 Enat,1e

•-• •••••• •-•r'"'""

- t::~r,s- t:::::
A»>21do01

Am31do01
}---NI'"--) r E.-
r

en0600003214

Click on Next.

Inverted function
By checking Invert function, a robot position is only considered hazardous if all
axes are inside their defined ranges.
Not inverted axis ranges and not inverted function:

Continues on next page

3HAC027709-001 Revision : J ongoing 43
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

If neither the axis ranges or the function is inverted, the safe zone (where no signal
is set low) is when all axes are inside their defined ranges. This safe zone
corresponds to the white area in the right picture below.
Axis 1

... . .
z -.. ··-- C:Of9,,t h ~ Mt ftftlt lf'i'll1b h ~ ~ -

..... ,1 ......,1 ..... ,1.,..,.1 ..... ,1

... ._......
... _.
"'"'1--:f
..:
- J - - r , i r , i - /- ",_ ,._
... ,1....
_ J--f>ir-,i-/- P t -
,._ -
~r=r=--Jl"l-
,. .
~~~
· 90 -30 4S 110

xx0700000436

Not inverted axis ranges and inverted function:

If the axis ranges are not inverted, but the function is inverted, the safe zone (where
no signal is set low) is everywhere except where all axes are inside their defined
ranges. This safe zone corresponds to the white area in the right picture below.
Axis 1

. ..
:, 18 0

z--··--
·-·1-,1-,1-·1-,1
ecn.,. ... M.- . . ~!MM) b lh ......~ r i

"""'~
.....
..... . ,._
- J - - , i i r , i - J - ",_
..:
68

.......
- 1--r-.r-.;-1- "·- -
r ..... -68

' * ~ r = -- Jr,-
,.
~~~
· 180
-90 -30 45 110

xx0700000438

Inverted axis ranges and not inverted function :

If the axis ranges are inverted but not the function , the safe zone (where no signal
is set low) is when all the axes are inside their defined ranges, i.e. when none of

Continues on next page

44 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

Continued

the axes are inside the undefined range in the middle. This safe zone corresponds
to the white area in the right picture below.
Axis 1

MoNwAmA-.,. ~
c..._. .. .._ .... ~f,Wl) b h M - . d ~ -

r--
..._______ ,._
_.
~~r-r--t-
_______
P'(,,ds

,._
'::~r.-r-- I-,..._

. 90 -30 4S 110

xx0700000437

Inverted axis ranges and inverted function :

If the axis ranges are inverted and the function is inverted, the safe zone (where
no signal is set low) is when one of the axes is inside the undefined range in the
middle. This safe zone corresponds to the white area in the right picture below.
Axis 1

__,
_______ .. _
.......
- ) - - r , i r , i- }- ,.,_

------·"-
~'-;-r-r-s-)- p ( .....

-90 ·30 45 11 0

xx0700000439

Example of how to use the inverted function:

A robot may have two working areas defined by axis ranges for axis 1 (MAR1 and
MAR2). To be able to move between these two working areas, axis 1 may be in
the range in between , under the condition that axis 2 is pointing up or backwards.
By defining MAR3 as axis one being between MAR1 and MAR2 and axis 2 pointing

Continues on next page

3HAC027709-001 Revision: J ongoing 45
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

forward , and inverting the function, the MAR3 signal will go low if both axis 1 and
axis 2 are pointing straight forward.
C,Wiz.vd I
Mo nitot Axi s Range ~
Carli<,.,• Ille Morilot - Rongo !MAR I 10< tho Mlloc:led N<hri:41 tri

0.-110.,...2
i;,,__ o.-J o....,•lo....,51

ROB_l
Aootl Jdogf
- t;::f"Tlj21--j-- p [r,,tje

• • - • •• •• • • • r '"'""
Mt 2fdogf
- j - - l ' f l i o - - - J "'~
• • • •• • • • • • r ,.,...

xx0700000443

;
/
;
;

MAR3

M AR3

xx0700000442

Continues on next page

46 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

Continued

Configure the Operational Safety Range

If using soft servo, the servo lag can easily exceed the limits for the function Control
Error Supervision. In this step of the wizard you can set axis ranges where the
tolerance for Control Error Supervision is higher.
For each axis, set the range where the tolerance should be higher {the red area).
Also set how high the tolerance should be. The tolerance {in degrees on arm side)
is specified in Tolerance.

Op a rotionel S eiley Range

Corl,go.,elhe ..,......,.,..,ei,.,,noelOSAllo lhe..i.cted_,....

F7 SoltS«vo[EnobleOSRI

J... 1[")
-)-J$f58-j-
l jio"j31ol<,..-.ce

-_2r_1-j-J66f11D---J
[ - jio"j31olel..-.ce

.knl)"J

l J--["zjjt50--J
- - - - - - - - - liT::3Tolelonce

en0600003215

Click on Next.

Set .s ync position

Jog the robot to the synchronization position used by Cyclic Sync Check or Software
Sync Check and click on Get actual position.
Sync Check Cycle defines the maximum allowed time {in hours) between
synchronization checks.
Before the cycle time has expired, a warning will be shown on the FlexPendant.
Pre-warning defines how long before the cycle time is up this warning should
occur.
When the cycle time has expired without a sync check, all output signals will go
low.
If a dual input signal is used for the synchronization check, connected to pin X10.5
and X10.6 on the 1/0 connector, select Dual Channel in the drop-down box. If a
single input signal is used, connected to pin X10.6, select Single Channel. If the

Continues on next page

3HAC027709-001 Revision: J ongoing 47
© Copyright 2006-201 2 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

Software Sync Check function is used, select Software Synchronization (only

available for EPS board 3HAC026271-001 revision 06 or later).
PS WlZatd

Synd u onous PoS.00

Plum defne IN aynchronou1 ~ iat Wiii •• the paratnllera fol ttw
•)"dwOf"ICll.llt meek.

s,....-
Goucoual pou.on I
R08_1
,-](deg)
s,....a-c...,.. 11>1
""'I (deg) .... 2(degl
fiT:B
(oo'"°:tf (oo'"°:tf (oo'"°:tf
AAa 4 (deg) ,_S(deg) ""'6(deg( JOUIIO>omol .:]
(oo'"°:tf (oo'"°:tf (oo'"°:tf

en0600003216

Click on Next.

Q Tip
Save the synchronization position as a r ob t arg et in your RAPID program. Also,
in the RAPID program, create a timer and program the robot to perform a
synchronization. Use a shorter cycle than the configured Check Cycle minus
Pre-Warning to avoid warnings on the FlexPendant.

Save and download to controller

From the last dialog in the wizard, you can:
• Save the motor calibration file. If no motor calibration has been performed,
this button is grayed out.
• Save the safety configuration file.
Download the motor calibration to the controller.
Download the safety configuration to the controller.

Continues on next page

48 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.2 EPS Configuration Wizard

Continued

!.Wizard

Co nfigur ation of EPS complde.

Yw CMlnow uvelhe corfigwat10nar dowricwldf 1othe CCl'lbait!f

Thof-..-.,.,..-.(,).,_beon"°""""ed
A09_1 M7

O<Jilill1tioad 10 Corilroh

en0600003217

Save motor calibration file

Save the motor calibration file so that you can load the values later, if required:
1 Click on Save to File under Motor Calibration. If no motor calibration has
been performed, this button is grayed out.
2 Select a file name and location for the file.

Save safety configuration file

Save the safety configuration file so that you can load the values later, if required :
1 Click on Save to File under Safety Configuration.
2 Select a file name and location for the file.

Download motor calibration to controller

Download the motor calibration to the controller:
Click on Download to Controller under Motor Calibration. If no motor
calibration has been performed, this button is grayed out.
2 A dialog informs you when the download is complete. Click OK.

Download safety configuration to controller

Download the safety configuration to the controller:
1 Click on Download to Controller under Safety Configuration.
2 A report of the safety configuration is shown, see picture below. The report
can be saved by clicking the Save button. By default the report is saved in
the folder C:\Documents and Settings\Username\Local Settings\Application
Data on the computer where EPS Configuration Wizard is running. The report
can be printed by right-clicking and selecting Print (it is recommended to
print the report since it should be used when validating the configuration as
described in Validate the configuration on page 58). Click OK to close the
report.
3 A dialog informs you when the download is complete. Click OK.
4 A PIN code for the configuration file is shown (which is also included in the
safety report). Write this PIN code down. You will need it when activating the
Continues on next page
3HAC027709-001 Revision: J ongoing 49
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.2 EPS Configuration Wizard

Continued

safety configuration on your system, see Activating the safety configuration

on page 56.

Roose check and conf1nn the oort,gur0100 The te"1 con be pnntod by nght·did<"' IM repon

AJlB S11f•t"· Councur.niou Rrpo1t

o ..u...·111 [ufonnanon
User Saf•tyUna Pm.85.<~
c-on.rID DAie 2008-0!>-18 U t? 5.9
M.chamcal U"' Nmne ROB_ I Sena! Number hfi-lO . U:l-1~

AddJnon.J Anr

N""" M1
J.oipca!A,a, 7
Scrt"o lq 10 1 (..dJ
Servo Oday F ac1or 2
M.asurmltlllBoard'l)pe DSQc:313
Measl.l'ement Node 7
Mea.swcrn.cnt Board Porrtson I
TrltUll'laSsaoo Rar:io :!()

R.....,.Move fme
Motor C<>111mWbon I 5708 (...dJ

en0600003363

Finish the EPS Configuration Wizard

1 Click on the button Finish.
2 Restart the controller (warm start).

50 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.3 Configuration for robots with non-zero calibration position

4.3 Configuration for robots with non-zero calibration position

Calibration position axis angles

Some robots have calibration positions with one or more axis angles that is not
zero.

xx0900000217

A Calibration marks, axis 3

B Calibration position, axis 1

Examples of non-zero calibration positions:

Calibration position values

Robot type Axis 1 Axis2 Axls3 Axis4 1Axis5 Axis6
IRB 5400-12 - Slim arm 40 ° o· 58.7° o· o· o·
IRB 5400-22- Process arm 40 ° o· so· o· lo· o·
To find the exact axis angles for a robot, look at the system parameter Calibration
Position in topic Motion, type Arm.

Effects on the EPS configuration

For robots with non-zero calibration position it is necessary to perform manual
corrections during the EPS configuration. Follow the description in EPS
Configuration Wizard on page 39 but adjust axis limits and sync position according
to the following descriptions.

Continues on next page

3HAC027709-001 Revision: J ongoing 51
© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.3 Configuration for robots with non-zero calibration position

Continued

Adjust axis limits

Adjust the axis limits by subtracting the calibration offset value from the real axis
limits you want to set up.

Example
A robot has a calibration position with a 40 ° calibration offset for axis 1.

Limit Desired axis limit Configured axis limit

Low 10 ° 10 ° - 40 ° = -30 °
--
High 75 ° 75 ° - 40 ° = 35 °

P5WU:.-ird

Monitor Axil Range ~

Comi,,e !he M-.. Am R.,.. jMAR) lo, !he .-...J - ""'

o.....,s...,.121 o.....,s.,...iJj o...,..s.,,.141 o.....,s.,,.1sl

r,...... i . -
ROB_f
Am1fd<gj
- 1=~ns--t=; r:;r....
••-••• • • ••-•r,. . .
A,u )(deg!
}---f-=r--J r En,t,io
r

e n0900000220

Continues on next page

52 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.3 Configuration for robots with non-zero calibration position

Continued

Adjust the sync position

Adjust the axis degree values of the sync position by subtracting the calibration
offset.

Example
A robot has a calibration offset of 40 ° for axis 1 and 60° for axis 3.
Click on Get actual position and get the following values:
ptj WiZMd I

s,..,-
Synchronou, PotilMJin

-
Pie~ defne lhe .,,-chonous P<*ian at wel .a, lhe paiame(e,1 tor lhe
...............

Getacowl-1
S,nc:0-t,delhJ
Alot2[doo[
Alot3fi]
~
!'2~ ~
Aloa5[deg) Aloa6(deg) 17 Ou.I Olamel "'•r.o

~ r:rr-3

en0900000221

Adjust the sync position by subtracting 40° from axis 1 and 60 ° from axis 3:
PS WiLG1d I

Synchronous Posillon
P1eMe defN lhe .,,-dwonous podlQf"I et wel .ei the parerne(er, for !he
.,.-chonou, c:heclc

Getacowl-1
ROB.I
s,..,a-c,c1ep,1
Aloa l [doo) ~ -2)deo) ~ Aloa3(doo) ,

~ ~
A>ot • [deo) A>ot5[deo)
~ J
A>ot6(deo)
'12:tl
17 0...,D,amel\<hr,g

~ ~ r:rr-3

en0900000222

3HAC027709-001 Revision: J ongoing 53

© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.4 Configuration for MultiMove

4.4 Configuration for MultiMove

Configuration file corresponding to drive module

In a MultiMove system there is one safety controller for each drive module that
uses Electronic Position Switches. A configuration file must be downloaded to
each safety controller. It is important that the configuration file downloaded to a
safety controller contains the configuration for those mechanical units controlled
by that drive module.

Multi Move system with 4 safety controllers

M

A B c D
en0600003310

A Safety controller 1 placed in the controller cabinet. Used to monitor robot 1 and
additional axis 1.
B Safety controller 2 placed in drive module 2. Used to monitor robot 2.

c Safety controller 3 placed in drive module 3. Used to monitor robot 3.

D Safety controller 4 placed in drive module 4. Used to monitor robot 4 and addi-
tional axis 2.
E Controller cabinet
- --
F Drive module 2
G Drive module 3
- -
H Drive module 4
I Robot1

J Robot2
K Robot3

L Robot4
M Additional axis 1

N Additional axis 2

Continues on next page

54 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.4 Configuration for MultiMove

Continued

How to configure EPS for MultiMove

When configuring a MultiMove system, follow the same procedure as described
in EPS Configuration Wizard on page39 tor the first safety controller (in the example
above: robot 1 and additional axis 1). When the configuration file is downloaded
to the controller, click on Finish and then start the EPS Configuration Wizard again.
Repeat this procedure once for every safety controller and make sure the selected
drive module corresponds to the mechanical units configured.

Controller Name IP Address

SEVST-W-0001562 12700 1

o,,... Setup
r Single

Onve 2
0nY0 3
Ottv11 4

en060000331 1

You will get one unique PIN code for each safety configuration file. Write these
PIN codes down.

D Note

Make sure that, for every configuration file, the configured mechanical units
belong to the selected drive module. The EPS Configuration Wizard will allow
you to configure any mechanical unit for any selected drive unit, but the result
will be an unexpected behavior.

3HAC027709-001 Revision: J ongoing 55

© Copyright 2006-2012 ABB. All rights reserved.
4 Configuration
4.5 Activating the safety configuration

4.5 Activating the safety configuration

Prerequisite
Before activating the safety configuration you must create the safety configuration
file and remember the PIN code for that file (see EPS Configuration Wizard on
page39).

Activation procedure

Action
When a safety configuration is downloaded to your robot system, the controller must
be restarted (warm start).
2 When the controller starts up, an elog message (20266) will ask for a safety controller
PIN code. Acknowledge this message.
3 Change user on the FlexPendant:
1 On the ABB menu, select Log off.
2 Tap Yes to confirm.
3 Select the safety user, type the password and tap on Login.
4 Make sure the controller is in manual mode.
5 On the FlexPendant:
1 On the ABB menu, tap Control Panel and then Safety Controller.
2 Tap the line and type the PIN code for the safety configuration file (see EPS
Configuration Wizard on page 39). Tap OK.
3 For a MultiMove system, enter one PIN code for each configuration file.
4 Tap OK.
ft ft 1
~
IA 01· ~
.Iii c ontrol Pane l -
Manual
S_513_ 0 175_SM (1 92.168.8 .77)

safety c ontroller
Guard Stop
Stopped (Speed 100'11.)

Any safety controller configuration must be

activated before being used by the system. For 7 8 9 +-
security reasons a PIN code is required .
Se lect the safety controller whose configuration you w ant to 4 5 6 _.
enable, enter its 4- digit PIN- cod e and tap OK.

80 3 Q9

Numerical S ignature :
90 212 142 3 103 30 162 38 160 79 127 57 70 43 46 2 19

View OK Cancel

[~1/0 ] ~ Control
Panel

en0600003332

Continues on next page

56 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.5 Activating the safety configuration

Continued

Action
6 When the PIN code is entered, a dialog will tell you if the PIN is correct. Tap Restart
in this dialog and the controller will restart.
If you typed an incorrect PIN code, the controller will restart anyway. Then you must
start over from step 2 of this procedure.
--
7 When the controller starts up, an elog message (20451) will say that a synchronization
is required. Acknowledge this message.
Perform a sync check. Note that the output signals are low until the sync check is
performed. This means that if you have connected to the Auto Stop on the panel board,
sync check must be performed in manual mode. If you have connected to General
Stop, the circuit must be closed in a safe way during the sync check. See Connect to
Auto Stop on the panel board on page 31 and Connect to General Stop on the panel
board on page 31 .
When the sync check is performed, an elog message (20452) will say that the robot
is synchronized. The Electronic Position Switches functionality is now active.

Safety configuration active until cold start

Once activated, the safety configuration is constantly active. Neither warm start
nor i-start of the controller will affect the safety configuration. However, a cold start
of the controller will remove all safety configurations.

3HAC027709-001 Revision: J ongoing 57

© Copyright 2006-201 2 ABB. All rights reserved.
4 Configuration
4.6 Validate the configuration

4.6 Validate the configuration

• DANGER

An Electronic Position Switches configuration must always be validated to verity

that the desired safety is achieved. If no validation is performed, or the validation
is inadequate, the configuration cannot be relied on for personal safety.

\J Tip

Do the following checks before you start the validation procedure:

1 Check the 1/0 signals according to section //0 connector data on page 25.
2 Create a safety user in the user authorization system and log in as a safety
user.
3 Carry out the synchronization procedure and connect the sync switch
according to description in section //0 connector data on page 25.
4 Set up the synchronization position in the EPS Configuration Wizard. Also
carry out a calibration offset.
5 Run the service routine for the function Cyclic Break Check.
6 Start the validation procedure.

Continues on next page

58 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 4 Configuration
4.6 Validate the configuration

Continued

About the validation

The safety configuration must be validated by the customer. This validation must
be performed every time a safety controller is configured. It is recommended that
the ABB Safety Configuration Report is printed and used as a formal document
for the verification. The document has rows where dates and signatures should
be written when the configuration is verified.

No Lo,....Lmt Uppe, 1 - Mo.. lm,de

I -105 115 ""'
2 -35 -15 r.i.,

Operational Safety Rance (only neces,an• (or Sonst"o)

Jon
No L<,wer I...arrm Upper 1.irM Tolcr1PCe
I -58 58 10
2 66 110 10
3 °230 50 12
-200 200 10
-115 115 10
6 -400 400 10
7 .90 180 10

c
en07000001 0 3

How to validate
Move the robot in and out of the configured zones and make sure all signals behave
the way they are supposed to.

3HAC027709-001 Revision: J ongoing 59

© Copyright 2006-201 2 ABB. All rights reserved.
4 Configuration
4.7 Viewing the configuration on the FlexPendant

4.7 Viewing the configuration on the FlexPendant

Accessing the configuration information

Action
1 On the ABB menu, tap Control Panel and then Safety Controller.
2 Tap the line for the safety controller you wish to view.
3 Tap View.

Configuration presentation

.ft 1111 [ GP, ] Manual Guard Stop

,,.... ~ Mia_EPS_ 5_13 (192. 168.8. 162) stopped ( Speed 100% )

Contro l Pane l - Safety Contro ller

PSC_Type= · sas1c•
PSC_HWVer sion = •1.o.o•
PSC_ConfigVer sion=•1.o.o•
Date= •2009- 12- 17 16:32: i s •

0 Mechanical _Unit
Contro ller ID= ..
User lD= ' Eps user•

0 Mon itoring
Pin= •679532'

0 OSR_Definition

0 SyncCheck

OK

en0900001052

60 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 5 Synchronization
5.1 Synchronization guidelines for Cyclic Sync Check

5 Synchronization
5.1 Synchronization guidelines for Cyclic Sync Check

Dual channel or single channel

Verify that the right type of synchronization (dual channel or single channel) was
selected in the configuration.
See Set sync position on page 47.

Uniquely defined position

The robot position for the sync check must be chosen so that the position of the
robot axes are unambiguously defined. One way to make sure the sync check
position is well-defined for all axes is to use the instruction MoveAbs J to move to
the sync position. See Technical reference manual· RAPID Instructions, Functions
and Data types.
Note that the sync position should be within the axis ranges configured for Monitor
Axis Range to avoid that the robot stops on the way to the sync position.

Small sync switch surface

For physical synchronization, the sync switch surface that the robot touches must
be small. The surface of the tool touching the sync switch must also be small. If
any robot axis moves one motor revolution, the robot must be out of reach for the
sync switch.

Always activate sync switch in the same way

For physical synchronization, always use the same tool. The robot should always
touch the sync switch with the same point on the tool.

Create RAPID program for synchronization

Create a RAPID program to perform a synchronization.This can be initiated from
a PLC or the main RAPID program. Perform the synchronization when the digital
output signal PSC1 CSPREWARN goes high. The PSC1 CSPREWARN signal is
only activated when Dual channel or Single channel synchronization has been
selected in the configuration. When Software synchronization has been selected,
it is only necessary to do a synchronization if the safety controller or the robot
controller has become asynchronous.
Write the program so that the robot first goes to a position close to the sync switch
and then approach it slowly from the desired direction. If the approach is too fast,
the accuracy of the robot position may be too low.

Example
In a system module elog 20470 is caught and an output signal is set. This signal
can be used by a PLC or a RAPID program.
MODULE SYNCINIT (sysmodule)
LOCAL VAR int n um irSyncPr eWarn;

Continues on next page

3HAC027709-001 Revision: J ongoing 61
© Copyright 2006-2012 ABB. All rights reserved.
5 Synchronization
5.1 Synchronization guidelines for Cyclic Sync Check

Continued

LOCAL TRAP tpSyncPreWarn

setDO doSyncPreWarn , 1 ;
TPWrite " SYNCHRONIZATION PRE WARNING . ";
RETURN ;
END TRAP

PROC initSync ()
CONNECT irSyncPreWarn WITH tpSyncPreWarn ;
! 20470 SC 1 Synchronization Pre-warn i ng
IError SYSTEM_ERR\Errorid := 470 , TYPE_ALL , irsyncPreWarn ;
ENDPROC

ENDMODULE

Synchronization on closing edge

The synchronization is executed 1 second after the sync switch is closed. The 1
second delay is implemented to avoid synchronization pulses before the manipulator
has stopped in its synchronization position.
Nothing happens when the sync switch is opened again.

Cyclic Sync Check output

Virtual output signals can be connected to physical output signals for
communication with a PLC. See also Virtual signals on page 67.

62 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 5 Synchronization
5.2 Synchronization guidelines for Software Sync Check

5.2 Synchronization guidelines for Software Sync Check

Selecting software synchronization

Verify that Software Synchronization was selected in the configuration.
See Set sync position on page 47.

Uniquely defined position

The robot position for the sync check must be chosen so that the position of the
robot axes are unambiguously defined. One way to make sure the sync check
position is well-defined for all axes is to use the instruction MoveAbs J to move to
the sync position. See Technical reference manual - RAPID Instructions, Functions
and Data types.
Note that the sync position should be within the axis ranges configured for Monitor
Axis Range to avoid that the robot stops on the way to the sync position.

Use easily verified sync position

Select a sync position where it is easy to verify the position of the robot axes. It is
helpful to use a position where the TCP touches a spike or something where it is
easy to see if the robot is in the correct position or not.

Use service routine to perform synchronization

& WARNING

If the robot position is not visually verified, to make sure all robot axes are in
correct position, the synchronization can jeopardize the safety.

D Note

Software synchronization can only be performed by a user with grants that allow
this, see Create a safety user on page 37.

Action
1 Move the robot to its sync position
(for example with MoveAbsJ).
- - - -
2 Visually verify that the robot is in If an axis is in wrong position, the revolution coun-
its sync position (all axes must be ters are most likely incorrect.
in correct position).

Continues on next page

3HAC027709-001 Revision: J ongoing 63
© Copyright 2006-2012 ABB. All rights reserved.
5 Synchronization
5.2 Synchronization guidelines for Software Sync Check

Continued

Action
3 In the program view, tap Debug mooo ix
and select Call Routine. 1\-- NewProgrMflarlll! n lJlOO l/MalnModule / maln

t-,-.M
" 'o
" 'o'"'U
.,.,-
LE,,.,,.
M_a_inM
ModuiM
_ o_ d.,..u-=1-e---,.,,.....l
•
r;.=;;.;_- =.lf"' ..
RautftM
~
•

• PROC main() 1r.;;;;;;;;;;.... l eu.-10~ l

'"' • ..... I _J
ENDPROC
• ENDMODULE !:> I.,. . . . . . _. l(a-.....,.
I J
... )

n~
1""1\Jtl lon
Edl ·1 Debug
. . ,.~·v
Position

en0400001109

4 Select the service routine Soft-

wareSync and tap Go to.
5 Follow the instructions in the ser-
vice routine.

64 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 6 Running in production
6.1 Reaction time

6 Running in production
6.1 Reaction time

Output signal response time

When a robot axis moves outside its configured range, the reaction time until the
safe digital output signal goes low is maximum 4 ms.

3HAC027709-001 Revision : J ongoing 65

© Copyright 2006-2012 ABB. All rights reserved.
6 Running in production
6.2 Recovery after safety violation

6.2 Recovery after safety violation

Auto Stop or General Stop

When an axis is outside its defined range, Electronic Position Switches sets an
output signal low. What is done with this signal depends on the installation. One
recommended way of connecting the output signals is so that they affect the Auto
Stop signal or the General Stop signal. See Connect to Auto Stop on the panel
board on page 31 and Connect to General Stop on the panel board on page 31 .

Recovery from Auto Stop

If an axis is outside its defined range and causes an Auto Stop:
1 Switch the controller to manual mode.
2 Jog the robot back within the defined ranges for all axes.
As soon as all axes are within their defined range, the Auto Stop is released
and you can continue.

Recovery from General Stop

If an axis is outside its defined range and causes a General Stop:
1 Switch the controller to manual mode.
2 Safely close the safety circuit (e.g with a dead man's handle) while jogging
the robot back within the defined ranges for all axes.
As soon as all axes are within their defined range, the General Stop is
released and you can continue.

66 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 6 Running in production
6.3 Virtual signals

6.3 Virtual signals

What is a virtual signal

The virtual signals can be viewed on the FlexPendant, but they are communicated
over the Ethernet connection and not a physical signal. They show the status of
signals from the safety controller and cannot be set by the user, which is why the
are represented as digital inputs (DI).
The virtual signals can be used by a RAPID program to produce helpful hints to
the operator of why the robot has stopped.

& WARNING

The virtual signals must not be used for safety implementation. Only the physical
signals can be used for safety implementation.

List of signals
Signal name Description
PSC1CSC Representation of the input signal from the sync switch to the safety
controller.
PSC1MAR1 Representation of the MAR1 signal from the safety controller.
PSC1MAR2 Representation of the MAR2 signal from the safety controller.
PSC1MAR3 Representation of the MAR3 signal from the safety controller.
--
PSC1MAR4 Representation of the MAR4 signal from the safety controller.
PSC1MAR5 Representation of the MARS signal from the safety controller.
PSC1 CSPREWARN Request to do synchronization check. The value is 1 if the prewarning
time for Cyclic Sync Check has expired.

All other virtual signals starting with PSC (Positional Safety Controller) are for
internal use. Do not use them for customer applications.

Signals for MultiMove system

In a MultiMove system there is one set of signals from each safety controller, i.e.
from each drive module that is equipped with a safety controller. Signals from drive
module 1 have names starting with PSC1 , signals from drive module 2 have names
starting with PSC2, etc.

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© Copyright 2006-2012 ABB. All rights reserved.
6 Running in production
6.4 Status LED

6.4 Status LED

Location of the status LED

A red/green status LED is placed on the front panel of the safety controller. It
indicates the status of the safety controller.

xx0900000242

IA IStatus LED

Status indications

LED indication Description

Solid green Safety controller CPU is running and communication is ok.
--- -
Solid red Internal hardware failure. Replace the safety controller.

Flashing green Communication failure or 1/0 power supply missing.

68 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 7 Example application
7.1 Example with two work zones

7 Example application
7 .1 Example with two work zones

Assignment
A robot cell consists of one robot and two positioners. The robot should be able
to work on a work piece held by one positioner while an operator change work
piece held by the other positioner.
There are two light curtains protecting that no personnel enters the station where
the robot is working.

~
~9 2 0

- -L__r - - - - - - - - - _

en0700000215
Light curtain 1
1_------- Light cu-tain 2
~: c 1:;.;;;;m...

Configure Monitor Axis Range signals

To implement the safety solution, two Monitor Axis Range signals must be
configured. The first signal should be high as long as the robot is not in station 1
(when it is safe for personnel to enter station 1). The second signal should be high
when the robot is not in station 2.
The following picture illustrates how these two signals are configured for robot
axis 1 in the EPS Configuration Wizard.

Me,....,Ax,. A....,. f,4,lfo

CMl9,,thW.-..._ R11,g,t~lli . . . . . . ~ w

_______ .. _
0..,1Jel,o,2!....,,1 ..... , 1....,,1
rJ......... ~
"°'-'
-11~
- } - - - r , ; i , a - )--- p , _

e n070000021 2

Continues on next page

3HAC027709-001 Revision: J ongoing 69
© Copyright 2006-201 2 ABB. All rights reserved.
7 Example application
7.1 Example with two work zones

Continued

The following picture shows the angles for robot axis 1 where the signals (MAR1
and MAR2) are high (green) and where they are low (red).

MAR1 MAR:

---------- o
Lig,t curtain 1
0 -----------
Lig,t cl.rtain 2
c:::r.:=-..,
en0700000214

Connecting signals to Auto Stop

This is a description of the principle for how to connect the signals. The light curtains
signals are high when they are untouched and low when the operator is in the
station. The safety condition that is to be implemented is that the operator and the
robot must not be in the same station.
Note that this illustration only shows single channels. In reality duplication will be
used for the following:
• dual output signals from the safety controller (e.g. MAR 1 A and MAR 1B)
• dual output signals from the light curtains
• dual Auto Stop signals (Auto Stop 1 and Auto Stop 2)
• implement the logical gates with two channel safety relays, two channel
safety PLC, or similar equipment

Continues on next page

70 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 7 Example application
7.1 Example with two work zones

Continued

ILight cu rtain 1 ILight curtain 2~

I IRCS
- - -,
~,
Safety I
contro ller
MARl
MAR 2
I
I
-
~, -

I
I
I
Panel I
board
I
I
Auto stop
&
I
L - - ----J

en0700000213

For more details about the connections, see section Hardware installation on
page 25.

D Note

The logical blocks in the picture are principal blocks. To make a safe installation
these blocks must be realized using safety components fulfilling relevant safety
standards for the installation.

D Note

If other safety equipment is connected to Auto stop, make sure that the safety
chain can be broken by any of the safety implementations.

D Note

Use dual channels in the real implementation.

3HAC027709-001 Revision: J ongoing 71

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This page is intentionally left blank
 8 Safety aspects for Electronic Position Switches
8.1 Overview

8 Safety aspects for Electronic Position Switches

8.1 Overview

Overview
Electronic Position Switches, EPS, is an additional safety computer in the IRCS
robot controller, with the purpose of providing safe output signals representing the
position of robot axes. The output signals are typically connected to cell safety
circuitry and/or a safety PLC which takes care of interlocking in the robot cell, for
example, in order to prevent robot and operator to enter a common area
simultaneously.
In this chapter we describe how EPS comply with relevant safety standards and
regulations.

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© Copyright 2006-2012 ABB. All rights reserved.
8 Safety aspects for Electronic Position Switches
8.2.1 Standards conformance

8.2 Safety requirements

8.2.1 Standards conformance

Standards
EPS has been designed to fulfill applicable parts of the following standards.
• EN ISO 12100-1 :2003 Safety of machinery- Basic concepts, general principles
for design - Part 1: Basic terminology, methodology
• EN ISO 12100-2:2003 Safety of machinery- Basic concepts, general principles
for design - Part 2: Technical principles
• EN 1050 Safety of Machinery, Principles of Risk Assessment
• EN 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
• EN ISO 10218-1 :2006, Robots for industrial environments - Safety
requirements - Part 1: Robot
• EN 61000-6-2 EMC, Generic immunity
• EN 61000-6-4 EMC, Generic emission
• EN 954-1 :1999 Safety of machinery- Safety related parts of control systems
- Part 1: General principles for design
• EN ISO 13849-1 :2006 Safety of machinery- Electrical equipment of machines
- Part 1: General requirements (will replace EN 954-1 in Dec. 2009)
• Applicable parts of ANSI/RIA R15.06-1999
• IEC 61508, Functional safety of electrical/electronic/programmable electronic
safety related systems
• IEC 62061, Safety of machinery - Functional safety of safety-related electrical,
electronic and programmable electronic control systems
• Applicable parts of UL 1740, "Industrial robots and robotic equipment"
• CAN I CSA 2434-03

74 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 8 Safety aspects for Electronic Position Switches
8.2.2 Specific safety requirements

8.2.2 Specific safety requirements

Specific safety requirements for Electronic Position Switches

Electronic Position Switches shall comply with EN ISO 10218-1 in general and
specifically comply with chapter 5.4, that is, the following requirements.
When safety related control systems are required, the safety related parts shall be
designed so that:
• A single fault in any of these parts shall not lead to the loss of the safety
function.
• Whenever reasonably practicable, the single fault shall be detected at or
before the next demand upon the safety function .
• When the single fault occurs, the safety function is always performed and a
safe state shall be maintained until the detected fault is corrected.
• All reasonably foreseeable faults shall be detected.
This requirement is considered to be of category 3 as described in EN 954-1 :1999
(EU harmonization of ISO 13849-1 :1999), which is the current and valid standard
for safety of machinery. Category 3 is normally fulfilled by redundant circuits, like
dual channels, which is the case for EPS. EPS together with the robot controller
also complies with performance level (PL) "d" according to EN ISO 13849-1 :2006,
and SIL 2 according to IEC 61508.

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© Copyright 2006-201 2 ABB. All rights reserved.
8 Safety aspects for Electronic Position Switches
8.3 Safe design of Electronic Position Switches

8.3 Safe design of Electronic Position Switches

Overview
Electronic Position Switches, EPS, has two important supervision functions.
The first one being to ensure that the axis computer and the drive system are
working correctly, making the robot follow the ordered value from the main computer
as expected.
The second being to supervise the robot position and setting outputs low to indicate
if the robot is in a hazardous area.

Supervision of axis computer and drive system

EPS is a separate and from the IRC5 independent device mounted in the drive
part, close to the axis computer.
The EPS board is connected to the communication link between the main computer
and the axis computer, thus reading the absolute motor position values sent as
reference to the axis computer. The EPS board is also connected to the
communication link between the Serial Measurement Board (SMB) and the axis
computer, and thereby reading the actual rotational motor position values. Since
these values are within one revolution, the absolute position is calculated by adding
values from internal revolution counters in both the axis computer and in EPS.
By comparing these values, that is the ordered motor position and the actual motor
position, Electronic Position Switches can detect any difference (outside a permitted
lag deviation) between the two positions, thereby ensuring that the drive system
is working properly according to the first supervision function as described above.
It is important to ensure that the safety controller and the robot controller are
synchronized. The safe sync position is defined during configuration and stored
in the safety controller. Synchronization can be done by activation of a switch or
by software depending on the application
To detect such errors, the robot can be ordered to go regularly to a synchronization
switch, which will generate a synchronization pulse to EPS confirming that the
robot revolution counter is correct. In some applications it is more feasible to do
the synchronization check by software.
In this position EPS will also calculate the robot joint positions and check against
a stored value to confirm that the synchronization is correct, covering the following
points.
• EPS is working correctly with the right revolution counter value.
• The right manipulator is used.
• The calibration value is correct.
• The SMB is working correctly.

Continues on next page

76 3HAC027709-001 Revision: J ongoing
© Copyright 2006-2012 ABB. All rights reserved.
 8 Safety aspects for Electronic Position Switches
8.3 Safe design of Electronic Position Switches

Continued

Category 3 supervision
This supervision complies with category 3, as described above, since two separate
channels that is, the axis computer with the drive system, motors, resolvers, and
measurement system (channel 1) and the ordered value from the main computer
(channel 2) shall always give the same result using the EPS evaluation circuits,
which in itself is dual c hannel, see illustration below.

Additional safety design

Additional safety, over and above what is formally required, is brought to the
concept by the inherent dual channel character of the resolver, thanks to its dual
sine and cosine output, where the square sum is supervised to be close to 1.
Also the single channel synchronization check is complying with category 3, even
if only one synch signal channel is used. The two channel requirement is in this
case fulfilled in two ways :
1 Check that the input signal is changing its value, that is has a flank, indicating
that the switch is working.
2 The double check of both receiving a physical synch pulse and the check
that the actual robot position corresponds to the stored value for the sync
position.

Continues on next page

3HAC027709-001 Revision: J ongoing 77
© Copyright 2006-201 2 ABB. All rights reserved.
8 Safety aspects for Electronic Position Switches
8.3 Safe design of Electronic Position Switches

Continued

Illustration, dual channel concept

r--------------------------------------------
SC
C1
AC OS

x2
C2

[ ___________________________________________ _
xx0800000198

C1 Channel 1
C2 Channel 2
x1 Actual value
x2 Ordered value
t-- -
AC Axis computer
DS Drive system
M Motor
R Resolver
SMB Serial measurement board
SC Safety controller (EPS board)

Supervision of robot position

The second supervision function (to supervise the robot position and setting outputs
low to indicate if the robot is in a hazardous area) is fulfilled by letting EPS compare
the robot position with limit values configured by an authorized user (so called
Safety User). If any axis (or combination of axes) is outside its defined safe area,
the supervision will activate an output. Active outputs are set to low, so that they
are valid also at power failure. There are five outputs which each can represent an
arbitrary combination of all robot axes (as selected by the Safety User).
To ensure that also this supervision complies with the category 3 requirement,
EPS is inside working with a two channel microprocessor based system, where
one channel is handling the actual position and the other the ordered position. The
outputs from EPS are also each consisting of two channels, thus preserving the
category 3 requirement.

78 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 8 Safety aspects for Electronic Position Switches
8.4 Certifications

8.4 Certifications

Overview
EPS has been certified by external organizations as described below.

BGIA concept certification

Berufsgenossenschaftliche lnstitut fur Arbeitsschutz in Germany made a concept
certification with the following result.
The concept of EPS complies with:
• Category 4 according to EN 954-1
• SIL 3 according to EN 61508
• Cat. 4 and PL e according to ISO 13849-1

D Note

Electronic Position Switches as a part of the IRC5 controller is category 3 and

PL d, even though the unit itself fulfills category 4 and PL e.

UL certification
EPS is approved by UL according to the following standards:
• UL 1740
• UL 1998
• ANSI I RIA R15.06
• CAN I CSA 2434-03
• ANSI I RIA 10218-1 :2007 (which is the US harmonized ISO 10218-1 :2006)

D Note

Since ISO 10218-1 :2006 thus is harmonized in EU as well as in North Americas,

the UL certification clearly shows that EPS fulfills the EU Machinery Directive.
In addition to this and since ISO 10218-1 refers to ISO 13849-1 :1999 as a
normative reference, it is also shown that EPS complies with the category 3
requirements.

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© Copyright 2006-201 2 ABB. All rights reserved.
8 Safety aspects for Electronic Position Switches
8.5 Conclusion

8.5 Conclusion

Conclusion
As has been shown above and confirmed by third party certifications, Electronic
Position Switches fulfills all relevant current safety standards globally.

80 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
 Index

Index
A
activating the safety configuration, 56 N
additional axes, 14 non-zero calibration pos ition, 51
additional axis, 28, 34, 41
Auto Stop, 31, 66 0
axis range, 17-18 occupationally safe, 16
operationally safe, 16
B Operational Safety Range
bus, 33 configuring , 23, 47
description, 22-23
c output signals, 26, 29
calibration position, 51
check cycle, 47 p
cold start, 57 panel board, 31
configuration file, 54 PIN code, 49, 56
connections, 25, 28, 30 PLC, 30, 32
continuous rotating axes, 17 power supply, 32
Control Error Supervision PSC1CSC, 67
description, 22-23 PSC1 MAR1, 67
current data, 26 PSC1 PREWARN, 67
Cyclic Sync Check
configuring, 47 R
description, 20 range, 17-18
guidelines, 61 reaction time, 65
recovery, 66
D redundancy, 27,29
download to controller, 48 relay, 30
drive module, 39, 54 robots, 14
dual input signal, 28
dual output signals, 29 s
safe input, 16
E safe output, 16
EPS Configuration Wizard, 39 safety, 11
safety bus, 33
F safety calibration file, 49
FlexPendant, 60 safety configuration, 56
safety controller, 13, 16, 25, 54
G safety relay, 30
General Stop, 31 , 66 safety user, 37
ground potential, 32 service routine, 63
servolag, 22-23, 47
signals, 26, 28, 30, 67
1/0 connector, 25, 30 antivalent, 16
1/0 signals, 28 equivalent, 16
independentaxes,40 single input signal, 28
inductive load, 29 SMB, 34
input signal, 26, 28 soft servo, 23, 47
invert function , 43 software installation, 35
i-start, 57 Software Sync Check
configuring , 47
L
description, 21
LED, 68 guidelines, 63
limitations SoftwareSync service routine, 63
safety controller, 14
status LED, 68
M supported additional axes, 14
mechanical unit, 40, 54 supported robots, 14
Monitor Axis Range sync check, 47
configuring, 43 synchronization
description, 17 description, 20-21
monitoring, 16 guidelines for Cyclic Sync Check, 61
motor calibration file, 49 guidelines for Software Sync Check, 63
motor calibration offset, 42 sync position, 20, 47, 61 , 63
MoveAbsJ, 61 , 63 sync switch, 28, 30
MultiMove, 39, 54, 56

3HAC027709-001 Revision: J ongoing 81

© Copyright 2006-2012 ABB. All rights reserved.
Index

T v
test pulses, 29 virtual signal, 67
tolerance, 47 voltage data, 26
tool , 61
w
warm start, 57

82 3HAC027709-001 Revision: J ongoing

© Copyright 2006-2012 ABB. All rights reserved.
Contact us

c:
"oic:
ABBAS ·a
C)
c:
Discrete Automation and Motion ..,
0

Robotics >
S-721 68 VASTERAS, Sweden "
a:
Telephone +46 (0) 21 344 400 0
0
a,
~
ABB AS, Robotics "'
0
()

Discrete Automation and Motion ~

Box 265 "'
N-4349 BRYNE, Norway
Telephone: +47 51489000

ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

www.abb.com/robotics

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