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ABB SafeMove2 Applications Manual

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ROBOTICS
Application manual
Functional safety and SafeMove2

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Summary of Contents for ABB SafeMove2

  • Page 1 ROBOTICS Application manual Functional safety and SafeMove2...
  • Page 2 Trace back information: Workspace 20C version a3 Checked in 2020-09-14 Skribenta version 5.3.075...
  • Page 3 Application manual Functional safety and SafeMove2 RobotWare 6.11.02 Document ID: 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 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, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Overview ....................3.4.2 Timing and error handling ................. System inputs and outputs .................. The Visual SafeMove user interface in RobotStudio About Visual SafeMove ..................Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 6 6.21 Restore configuration ..................6.22 Reset safety controller to factory settings .............. 6.23 Upgrading and installing new systems ..............Running in production Reaction time ....................Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 7 10.5.3.6 Safe zones ................. 10.5.4 Example ....................10.6 How to establish CIP Safety communication with a PLC ........... 10.6.1 Introduction .................... 10.6.2 Configuring the ABB CIP Safety Adapter in Studio 5000® ....... Index Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P...
  • Page 8 This page is intentionally left blank...

  • Page 9: Overview Of This Manual

    Product manual - IRC5 3HAC047136-001 IRC5 of design 14 Technical reference manual - RAPID Instructions, Functions and 3HAC050917-001 Data types Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 10 Restore configuration on page 186. • Added section Upgrading and installing new systems on page 188. • Minor corrections. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 11 SafeMove now supports MultiMove systems with four robots, see MultiMove on page • Minor corrections. Released with RobotWare 6.07. • Changed manual name to indicate that it covers the function SafeMove2 and not SafeMove1. • SafeMove now supports Stand alone controller, with some restrictions. Limitations on page •...
  • Page 12 • Updated screenshots in Configuring SafeMove on page 137. • Added a new section for Feedback coupling in Pre-logic and post-logic on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 13: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics 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.
  • Page 14 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 troubleshooters. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 15: Safety

    The integrator of the robot system is responsible for the safety of the robot system. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 16 This page is intentionally left blank...

  • Page 17: Introduction

    Manual workpiece inspection during operation • Optimization of cell size • Protection of sensitive equipment • Ensuring safe orientation of emitting processes Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 18 Axis Position Supervision Axis Speed Supervision Total Global Supervision Tool Orientation Supervision Tool Position Supervision Tool Speed Supervision Stand Still Supervision Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 19 The validation must also consider that the braking starts after a zone is violated, so additional stopping distances may be required, which depend on many factors, for example mass and speed. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 20: Safety

    Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 21: Standards Conformance

    EN ISO 13849-1:2015 Safety of machinery - Electrical equipment of machines - Part 1: General requirements EN ISO 13849-2:2012 Safety of machinery - Safety-related parts of control systems - Part 2: Validation Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 22: Specific Safety Requirements

    (PL) "d" according to ISO 13849-1. This safety level is equivalent to SIL 2 as defined in IEC 61508. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 23: Safe Design Of Safemove

    1. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 24 SafeMove is internally working with a two channel microprocessor based system. Both processors make parallel calculations comparing the actual position and the reference position. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 25: Certifications

    • CAN/CSA Z434-14, Industrial Robots and Robot Systems - General Safety Requirements • CAN/CSA C22.2 No. 73-1953, Test of Electrically Operated Machine Tools Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 26: Conclusion

    As has been shown above and confirmed by third party certifications, the safety module and SafeMove fulfills all relevant current safety standards globally. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 27: Limitations

    • Compact controller [700-8]. Robots supported by the safety module The safety module, without a SafeMove option, supports all ABB robots that can be ordered with the above controller variants. Safe fieldbus options The safe fieldbus options can be used on all robots that supports the safety module.
  • Page 28 SafeMove supports any mounting angle. For example floor mounted, tilted, inverted, etcetera. Supported tracks SafeMove supports all ABB track motion units. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 29 SafeMove option but this needs to be verified case by case. To verify if a non ABB additional axis can be used with SafeMove, tune the additional axis before configuring the SafeMove parameters. If a properly tuned and configured non ABB additional axis still generates error messages regarding servo lag, then it cannot be used with SafeMove.
  • Page 30 If the safety module is used, it is not allowed to connect any signal to the Superior Stop input on the Panel Board. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 31 (CAP) in the area where SoftMove is active. For more information about SoftMove, see Application manual - Spot options and Application manual - SoftMove. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 32: Terminology

    Dual monitored digital input. Safe output Dual monitored digital output. Safety controller A safety board used with the robot controller, handling Safe- Move functionality. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 33: Abbreviations And Acronyms

    Abbreviation/acronym Description Axis Position Supervision Axis Speed Supervision Contact Application Tolerance Stand Still Supervision Tool Orientation Supervision Tool Position Supervision Tool Speed Supervision Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
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  • Page 35: Safemove Functions

    Local functions are active when the robot is in defined parts of its working area, it could be inside a safe zone or within specified ranges. Those functions are used Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 36 1 stop and the completing category 0 stop. • No safety supervision of manual reduced speed. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 37 A SafeMove 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. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 38: General Functions

    Manual Operation Supervision is activated by switching to manual mode. Dependencies to other supervision functions Manual Operation Supervision can be used in combination with all other SafeMove functions. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 39: Contact Application Tolerance (Cap)

    If Contact Application Tolerance is active, it overrides the Control Error Supervision function. That means that all other active safety controller functions work with relaxed Control Error Supervision. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 40 Limitations Contact Application Tolerance is not considered to be active if the run chain is open. Related information Control Error Supervision on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 41: Synchronization Functions

    Related information Configure the synchronization position on page 148 Software synchronization guidelines on page 197. Recovery after safety violation on page 191. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 42: Hardware Synchronization

    Related information Configure the synchronization position on page 148 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 43 2 SafeMove functions 2.3.2 Hardware synchronization Continued Hardware synchronization guidelines on page 199. Recovery after safety violation on page 191. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 44: Supporting Functions

    Stops initiated elsewhere, e.g. by the robot controller, are not supervised. Related information Category 1 stop (see Terminology on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 45 2 SafeMove functions 2.4.1 Safe Brake Ramp Continued Category 0 stop (see Terminology on page Explanation of Safe Brake Ramp on page 90 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 46: Supervision Functions

    The following parameters can be configured for Stand Still Supervision: • Assignment of safe inputs for activation of Stand Still Supervision. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 47 Supervision function will be deactivated. A movement with reduced speed is possible. Limitations • Stand Still Supervision is only available for SafeMove Pro, see Functional safety options on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 48: Axis Speed Supervision (Asp)

    • The highest speed limit that can be configured is 600 degrees/s for rotational axes and 10000 mm/s for linear axes. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 49: Tool Speed Supervision (Tsp)

    MoveJ or MoveAbsJ. If this occurs, either increase the Max Speed for Tool Speed Supervision, or try to add intermediate robot targets in the RAPID program. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 50 • The highest speed limit that can be configured is 600 degrees/s for rotational axes and 10000 mm/s for linear axes. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 51: Axis Position Supervision (Apo)

    164. Function activation Axis Position Supervision is activated by a safe input signal, or is permanently active. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 52 The braking distance depends on robot type, load, position and speed, and therefore an additional stopping distance may sometimes be required to achieve the desired safety. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 53: Tool Position Supervision (Tpo)

    The braking distance depends on robot type, load, position and speed, and therefore an additional stopping distance may sometimes be required to achieve the desired safety. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 54: Tool Orientation Supervision (Tor)

    Tool Orientation Supervision is activated by a safe input signal, or is permanently active. Limitations • Tool Orientation Supervision is only available for SafeMove Pro, see Functional safety options on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 55: Control Error Supervision

    Control Error Supervision is always active. It can only be relaxed by Contact Application Tolerance. Dependencies to other functions If Contact Application Tolerance is active, then Control Error Supervision is relaxed according to user definitions. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 56 This page is intentionally left blank...

  • Page 57: Installation

    For information on how to install the Safety module, see Product manual - IRC5. xx1500001760 Safety module DSQC1015 PCIexpress slot for other devices. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 58: Sync Switch

    If hardware synchronization is used, a sync switch should be connected to a safety PLC and communicate with the robot controller via PROFIsafe. Robot Controller PROFIsafe Safety Safety controller Sync switch xx1600000249 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 59: Software

    SafeMove on the robot controller. Use RobotStudio to configure, build, and download a RobotWare system to the robot controller. For more information see Operating manual - RobotStudio. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 60: Safe Fieldbuses

    The replacement of safety devices requires that the replacement device is configured properly, and the operation of the replacement device must be verified by the user. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 61 EtherNet/IP, with device mapping outside of the user-defined input and output size. That area is used by PROFIsafe and CIP Safety and the signals will be overwritten. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 62: The I/O Engineering Tool

    PROFINET or EtherNet/IP networks. In future releases it will also support other networks. For more information, see Application manual - PROFINET Controller/Device or Application manual - EtherNet/IP Scanner/Adapter. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 63: Cip Safety Adapter

    RobotStudio or the robot controller. • In the RobotWare installation folder in RobotStudio: ...\RobotPackages\ RobotWare_RPK_<version>\utility\service\EDS\ • On the IRC5 Controller: <SystemName>\PRODUCTS\ <RobotWare_xx.xx.xxxx>\utility\service\EDS\ Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 64 Clearing a pre-existing configuration The first scanner (originator) that successfully establishes a producing connection to the ABB CIP safety adapter becomes the owner of that adapter's inputs. It is necessary to reset the ownership when the originator's SNN or NodeID is changed.

  • Page 65: Profisafe F-Device

    PROFIsafe F-Device on the robot controller. Installation For information on how to connect and configure the PROFINET industrial network, see Application manual - PROFINET Controller/Device. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 66: Profisafe F-Host

    PROFIsafe F-Host operator acknowledge on page 115. • By setting the system input ProfiSafeOpAck, see Activate the system inputs and outputs on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 67: Abb Ci502 Profinet I/O Device

    A RobotWare license with the options PROFINET Controller/Device and Prepared for ABB CI502 is required to host ABB safe I/O devices on the robot controller. The required GSDML file for setting up the ABB S500 safe I/O devices is included by default in the I/O Engineering Tool.

  • Page 68: Remote Control Of Operating Mode

    [735-8] Keyless Mode Selector, 2 modes • The robot system must be installed with the base RobotWare option Auto Acknowledge Input enabled in Installation Manager. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 69: Timing And Error Handling

    The robot controller will change to manual reduced speed mode when all of the following conditions apply: • Manual reduced speed is requested • Remote control enable is active xx1700000467 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 70 If the PLC requests a mode change to automatic mode but does not acknowledges it within 10 seconds, then the system is set to manual reduced speed mode and an event log is issued. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 71: System Inputs And Outputs

    Add the system outputs to the group SYSSIG_OUT in the same way. Save the file and reload it to the controller. Restart the system to activate the signals. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 72 This page is intentionally left blank...

  • Page 73: The Visual Safemove User Interface In Robotstudio

    Only a user with the grant Safety Services is allowed to download a configuration. See Set up safety user grants on page 141. Limitations The simulation functions are only available when running a RobotStudio station. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 74: The User Interface

    SafeMove, see The Visual SafeMove tab on page 76 The Modify tab on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 75 Zone maxim- Robot allowed Robot not al- cluded in Tool um speed lim- um speed lim- inside zone lowed inside Position Su- zone pervision Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 76: The Visual Safemove Tab

    Configuration group The Configuration group is used when creating, saving and loading SafeMove configurations. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 77 The Safe IO Configurator button is used to start the SafeMove IO configurator. The safe IO configurator is described in a separate chapter, see The Safe IO Configurator on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 78 Options group The Options group contains display options for the Visual SafeMove user interface. Checkbox Description Show Labels Displays labels in the graphics window. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 79: Adding Safemove Functions

    By default all eight points are created. It is recommended to reduce the number of points if all points are not required depending on the shape of the tool. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 80 Height The height of the zone. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 81 The settings for the global safety functions are the same as for the safe zones and safe ranges. For information about the settings see The Add Safety Function group on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 82 A triggered safety stop from the safety PLC will always trigger a protective stop on the superior stop input (SS) of the IRC5 panel board. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 83 The minimum servo lag used for detecting that the cyclic brake threshold check is performed. ROB1 If a checkbox is deactivated, then cyclic brake check is deactivated for that joint. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 84: The Modify Tab

    The following function is only available for safe zones: Button Description Tool Position Supervision Tool Position Supervision (TPO) on page 53 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 85 Function Setting Description Speed limits The minimum and maximum speed for each robot joint. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 86 The minimum and maximum speed for the tool. Tolerances Specifies if Stand Still Supervision is enabled and the toler- ance for each robot joint. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 87: The Visual Safemove Browser

    In Basic joint supervision mode, no safe zones or tool super- vision functions are allowed. Overview of SafeMove functions on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 88 SafeMove in manual reduced speed mode. For more information, see Technical reference manual - System parameters. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 89 The value is specified for the arm side. Start speed offset A speed offset for the Safe Brake Ramp function. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 90 The axis position values of the robot. • Joint • Position Additional axis The axis position value of the additional axis. • Joint • Position Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 91: The Safe Io Configurator

    Configure safe I/O on page 152. For information on general rules and limitations see Safe I/O system rules and limitations on page 108. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 92: Signals View

    Parameters for CIP Safety internal adapter Setting Description NodeId The same as the IP address of the internal safety adapter device. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 93 Configuration signa- The configuration signature, also called Safety Configuration ID ture (SCID), uniquely identifies the configuration of the ABB CIP Safety Adapter and can be used to confirm the integrity of the adapter configuration over time. The signature is checked whenever an originator tries to connect to the adapter.
  • Page 94 Lists all readers and writers of the signal. A signal can only have one writer, but it can have more than one reader. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 95 PROFIsafe F-Device signals The safe input and output signals for PROFIsafe F-Device are located on the PN_Internal_Device on the PROFINET bus. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 96 CIP Safety Adapter signals The safe input and output signals for CIP Safety Adapter are located on the EN_Internal_Device_Safe on the EthernetIP bus. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 97: Function Mappings

    True if Commissioning mode is selected. Use this to check, in the robot controller I/O system, if Commissioning mode is active. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 98 Not used in the standard delivery. Only used for option SafeMove Basic or SafeMove Pro. Only with safe fieldbus option (997-1, 997-2, 997-3 or 997-4). Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 99: Pre-Logic And Post-Logic

    First use the button Create signals to automatically create global signals from the statement, then use cut and paste to move signals to safe inputs or outputs. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 100 COPY Copy integer value. COPY(Source, Destination1, Destina- tion2,...,Destination8) Copy integer value from source to up to eight destination signals. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 101 1. Multiplexer between two integer values. Remainder, modulo, after division with boolean error flag when dividing with zero. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 102: Description Of The Complex Operators

    The integer resultant count is limited by the value of the integer actuator period. When count reaches period, then count will restart from 0 (zero) on the next Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 103 I.e. for integer values between 8 and 15, (1xxx). Maximum one output will ever be activated at the same time. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 104 This operator divides two integer actuators and produces the quotient as an integer resultant. If the denominator act2 is zero, then error is set and res1 keeps its current value. xx1800002602 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 105 EDGE operator sets result to active upon a transition, from inactive to active, on reset. xx1800002603 xx1700000469 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 106 If the denominator act2 is zero, then error is set and res1 keeps its current value. xx1800002605 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 107 4.6.4.1 Description of the complex operators Continued Feedback coupling The feedback coupling feature refers to using the resultant integer output as an input to the same operator. xx2000001823 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 108: Safe I/O System Rules And Limitations

    8 operands to an AND function. These additional operators are also counted from the limit of 100. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 109: Simulating Safemove

    The function creates a Tool Orientation Supervision where the tolerances around the x and z axis of the tool are calculated from the simulation. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 110: Protected Basic Configuration

    The write-protected element are visualized checkboxes in the tree structure. with a padlock icon in the Visual SafeMove browser. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 111 Elements browser. However, this will affect the protected elements checksum. Therefore it is necessary to verify the protected elements checksum for each system. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 112 This page is intentionally left blank...

  • Page 113: The Flexpendant User Interface

    Use this procedure to start the Safety Controller window. Action Tap the ABB menu. Tap Control Panel and Safety Controller. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 114 For a more user friendly view, use RobotStudio to view configuration, or create a new report. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 115 An emergency stop on the controller will not be forwarded to the safety PLC or any other equipment if the robot controller is in commissioning mode. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 116 Green - OK • Yellow - Warning • Red - Error • Grey - Undefined, no information is present. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 117 Starts the service routine and performs a Cyclic Brake Check. Note All drive modules with a CBC configuration are targeted when executing the service routine. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 118: The Keyless Mode Selector

    For more information about changing operating modes, the Quickset menu, and the FlexPendant in general, see Operating manual - IRC5 with FlexPendant. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 119 If the PIN-code is lost or forgotten it is possible to unlock the operating mode for a user with the grant Key-less mode selector, see User authorization (UAS) on page 114. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 120 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 121: Safemove Visualizer

    The main menu of Safemove Visualizer is displayed. For more information on how to use the FlexPendant in general, see Operating manual - IRC5 with FlexPendant. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 122 Controller control panel on page 113. Display details Menu button for displaying the data declaration of the zones, supervision status, and active tool data. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 123: The Safe Zone Config Tab

    Menu button for displaying the data declaration of the zones, supervision status, and active tool data. See Zone data in the Safe Zone Config tab on page 129. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 124 The status of a safety zone is identified with the following colors in the graphical display: • Green - Zone is deactivated • Yellow - Zone is active • Red - Zone is active and violated Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 125: Navigating The Graphical View

    Diagram level Menu selection (for XY-Rotation angle 0°) Plan view Front view Rear view Side view from the right Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 126 The graphic will be updated immediately when an angle is selected. Close the dialog by tapping the confirm button. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 127: Depth Change In The Side View Of The Graphical Display

    The depth that has been adjusted using the arrow buttons is displayed in the information box above the buttons in millimeters. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 128 If the box is completely white, you have reached the end of the robot cell and all zones and the robot are behind you. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 129: Zone Data In The Safe Zone Config Tab

    Zone activation, the zone points, the zone height, and other zone data is displayed in the tab. You can switch between existing zones using the menu buttons "< Zone" and "Zone >". xx1600000225 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 130: The Last Zone Violation Tab

    Zoom level is modified in such a way so that the tool geometry, the TCP, and the wrist flange are visible. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 131 The directions of the tool coordinate system are shown on the wrist flange with lines in the colors red (X-axis), green (Y-axis), and blue (Z-axis). xx1400001314 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 132 Only the violating geometry is shown. The TCP is shown as a filled star. xx1600000224 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 133: Zone Data In The Last Zone Violation Tab

    The activation status of the displayed supervision is indicated by a LED with the following colors: • Yellow LED - Supervision is active • Grey LED - Supervision is inactive Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 134 The data for the violated tool is displayed in the violated tool tab. xx1600000091 Tap a tool geometry in the list to view the characteristics in a larger window. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 135: The Safe Ranges Tab

    Yellow - Axis range supervision is active. Violation The last violation can be viewed by clicking the Last Violation button. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 136 5.3.4 The Safe Ranges tab Continued Both axis position violations and tool position violations can be viewed. Axis position violation xx1600000093 Tool position violation xx1600000095 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 137: Configuring Safemove

    Load the configuration to the safety controller controller. on page 171 Restart the robot controller. Validate the configuration. Validate the configuration on page 173 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 138 Set the safety configuration to validated Setting the configuration to validated on and lock it. page 184 Setting the configuration to locked on page 185 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 139: Preparations

    Create tool data for all needed tools, and define the TCPs, tool loads, payloads, and arm loads. • Create work object data for all needed fixtures and define them. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 140: Configure System Parameters

    SafeMove will trigger overspeed error when robot and track is moved simultaneously. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 141: Set Up Safety User Grants

    Lock Safety Controller configuration • Safety services • Key-less mode selector • Write access to controller • Manage UAS settings Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 142 Safety Services Lock Safety Controller Configuration Software synchroniza- tion Key-less mode selector Commissioning mode Remote restart Program debug Read access to control- ler disks Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 143: Starting Visual Safemove

    In the Controller tab, click Online Monitor. (Not needed when running a RobotStudio station.) In the Controller tab, click Safety, then select Visual SafeMove. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 144: Configure Manual Operation Supervision

    See also system parameters Teach Mode Max Speed and Use checkpoint limitation in world in section Configure system para- meters on page 140. xx2000001832 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 145: Configure The Robot

    Automatically create encapsulation In the SafeMove ribbon, click on Encapsulate Upper Arm. This will create a geometry surrounding the upper arm. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 146 Click on the shape you have just created to select it. Fill in the parameters for the shape to specify the position and size of the shape. xx1600000129 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 147: Configure Additional Axes

    Some information about the additional axis is shown, but cannot be changed. This includes joint limits, transmission gear ratio and measurement channel information. xx2000001834 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 148: Configure The Synchronization Position

    It is also possible to specify the axis position ition. values manually. In the Visual SafeMove Properties browser, click on Read current values. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 149: Configure The Tools

    Manually create a SafeMove tool Action Note/illustration In the SafeMove ribbon, click on the Tool menu and select New. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 150 In the ribbon, click on a geometry (Sphere, Capsule, or Rounded box). Click on the shape you have just created to select it. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 151 The parameter values can then be adjusted. Deleting a tool Action Right-click on a tool and select Delete object. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 152: Configure Safe I/O

    It is possible to use a spreadsheet application, or text editor, to edit the names of the signals and then copy-paste them into RobotStudio. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 153 Use the Function mappings view of the Safe IO Configuration to select which signal to use for each function. xx1600000139 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 154 It is recommended to configure the post logic after configuring the supervision functions. An error message is shown if a signal value is used in a logical expression without having a defined writer. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 155: Configure The Zones

    Y while dragging, the dragging is done along the Y-axis while the X value re- mains unchanged. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 156 In the Visual SafeMove ribbon, click on the function to create. Configure the function according to Con- figure the supervision functions on page 160. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 157: Configure The Ranges

    To change the name of a range, right-click on the range in the Visual SafeMove browser, select Rename and type the desired name. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 158 In the Visual SafeMove ribbon, click on the function to create. Configure the function according to the descriptions in section Configure the su- pervision functions on page 160. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 159: Global Supervision Functions

    In the Visual SafeMove ribbon, click Global Functions and select function. Configure the function according to Con- figure the supervision functions on page 160. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 160: Configure The Supervision Functions

    If the robot must be inside the zone, se- lect Allow inside. If the robot must be outside the zone, clear the check box Allow inside. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 161 Specify the maximum allowed speed in The maximum speed limit must always be Max speed. larger than the minimum speed limit. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 162 In Stop category, select if violation of the function should stop the robot with cat- egory 0 stop, category 1 stop or not stop the robot. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 163 No signal. Signal definitions: 0 = at least one violation action is disabled 1 = all violation actions are enabled Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 164 If an activation signal should be used, select which input signal should be used to activate this Axis Position Supervision function. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 165 If an activation signal should be used, select which input signal should be used to activate this Contact Application Toler- ance function. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 166 If no activation signal should be used, select Permanently active, but then Stop category must be set to NoStop. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 167 (in radians on axis side). Select Allow in Manual Mode if the super- vision should be active in manual mode. xx2000001843 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 168: Configure Other Functions

    In Signal behavior, select the behavior of the signal. For more information, see The General Output button on page Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 169 Check for axis to On via RobotStudio for all axes not included. For more information, see Cyclic Brake Check guidelines on page 200. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 170: Save The Configuration

    Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 171: Load The Configuration To The Safety Controller

    SafeMove. This makes it easy to view the configuration or to make changes to it and download it again. Action In the Visual SafeMove ribbon, click on Controller and then select Read from control- ler. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 172: Configuration For Multimove

    Just right-click on the item to copy and select Copy, then right-click on the destination and select Paste. The robots are shown under each other in the Visual SafeMove browser. xx2000001844 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 173: Validate The Configuration

    Depending on the combination of functions and how they are activated, the validation procedures described below may have to be modified for the specific configuration. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 174 Validate the range limits for all configured ranges. It is enough to validate the limits of each range for one function, since the range limits are treated equally for all Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 175 If not permanently active, activate the activation in- put signal for Tool Speed Supervision for the range. Deactivate all other supervision functions that are signal activated. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 176 If a zone has a Tool Position Supervision function, perform the validation for that function. See Tool Position Supervision validation on page 179. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 177 If the system is equipped with a track motion, check that the tool zone border is in correct position for different positions of the track motion. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 178 For each tool, perform the validation for Tool Speed Supervision with that tool. See Tool Speed Supervision validation on page 180. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 179 Orientation Supervision zone or all axes inside the range. If used, verify that the corresponding function active Status signal is 1. status signal is set. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 180 TCP. Use MoveAbsJ, moving axis 5 or 6, to rotate the tool. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 181 Repeat this for both lower and upper limit of the axis range. Repeat this for all axes configured for Axis Position Supervision, including additional axes. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 182 If the Stand Still Supervision is configured to stop at violation, determine that the movement until the robot is stopped again is within a tolerable limit. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 183 Relevant operating modes are: • SC_GeneralStop: All modes • SC_AutoStop: Automatic mode • SC_EmergencyStop: All modes. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 184 Log in as a user with the grant Safety Set up safety user grants on page 141. Services: 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.
  • Page 185 Log in as a user with the grant Lock Set up safety user grants on page 141. Safety Controller Configuration: 1 On the ABB menu, select Log off. 2 Tap Yes to confirm. 3 Select the safety responible user, type the password and tap on Lo- gin.

  • Page 186: Restore Configuration

    Select the file sc_cfg.xml and click Open. The Restart Controller dialog is shown when the safety configuration has been downloaded. Click Yes to restart the controller. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 187: Reset Safety Controller To Factory Settings

    171. Note It is also possible to reset the safety controller to factory settings from RobotStudio, see Configuration group on page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 188: Upgrading And Installing New Systems

    For information on locking the safety configuration, see Setting the configuration to locked on page 185. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 189: Running In Production

    When a signal is set to 0 at violation, it will remain 0 for at least 250 ms even after the violation has ended. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 190: Restarting The Controller

    The SafeMove safety configuration file is included in the backup. For information on how to restore the SafeMove safety configuration, see Restore configuration on page 186. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 191: Recovery After Safety Violation

    Note Press the motors on button on the robot controller. This allows the robot to be moved at reduced speed. Perform a synchronization. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 192: Changes To Robot Or Robot Cell

    Perform synchronization If any of the following is done, a new synchronization is required: • Revolution counter update • Fine calibration • Axis calibration Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 193: Maintenance

    Internal functions are self tested All internal functionality in the SafeMove safety controller is subject to self tests and requires no maintenance activities. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 194 This page is intentionally left blank...

  • Page 195: Rapid Components

    Data types There are no RAPID data types for functional safety and SafeMove. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 196 This page is intentionally left blank...

  • Page 197: Reference Information

    (all axes must be ters are most likely incorrect. in correct position). Go to the Safety Controller view. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 198 10 Reference information 10.1.1 Software synchronization guidelines Continued Action On the tab Synchronization, tap Synchronize. xx1500000806 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 199: Hardware Synchronization Guidelines

    If the RAPID instruction SafetyControllerSyncRequest is executed and no sync signal is received within 30 seconds, the robot is stopped with an error message and the safety controller becomes unsynchronized. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 200: Cyclic Brake Check Guidelines

    Action Note/illustration Move the robot to a safe brake check position. On the FlexPendant, open the Safety Controller view. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 201 VAR syncident sync1; VAR syncident sync2; IF PLC_di1_DO_CBC = 1 THEN WaitSyncTask sync1, task_list; CyclicBrakeCheck; WaitSyncTask sync2, task_list; ENDIF T_ROB2 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 202 Max Static Arm Torque = Tbrake min/1.35 Tbrake min for ABB motor units can be found in the product specification for the specific motor unit, see Product specification - Motor Units and Gear Units. Note Note that the calculated value should be entered in [Nm] and calculated to the motor side.
  • Page 203 For more information see parameter Brake Maintenance, type General Rapid, topic Controller, in Technical reference manual - System parameters. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 204: Cyclic Brake Check Signal Description

    Set to SC1CBCOK SC1CBCREQ SC1CBCACT New configuration downloaded, synchronization done, no CBC done Signal Signal state SC1CBCOK SC1CBCREQ SC1CBCERR SC1CBCWAR Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 205 SC1CBCACT SC1CBCPREWARN Max. allowed speed: Max speed CBC done with the result ERROR Signal Signal state SC1CBCOK SC1CBCREQ SC1CBCERR Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 206 SC1CBCWAR SC1CBCACT SC1CBCPREWARN No change Interrupted CBC test, program pointer moved from CBC routine Signal Signal state SC1CBCOK SC1CBCREQ Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 207 10 Reference information 10.2.1 Cyclic Brake Check signal description Continued Signal Signal state SC1CBCERR SC1CBCWAR SC1CBCACT SC1CBCPREWARN No change Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 208: Servo Delay Factor And Servo Lag

    Lag has to compensate this since the difference between reference and measured motor angular position will be large when the axis accelerates, runs at high speed, or decelerates. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 209 Tuning a non ABB additional axis If attempting to use a non ABB additional axis, start with doing a tuning of the axis. To be able to reduce servo lag below the configured maximum allowed value during the tuning, make sure to set the parameter FFW Mode (feed forward mode) to Spd (speed) or Trq (torque).

  • Page 210: Connection Of External Emergency Stop

    Robot Panel 24 V board 24 V External Local emergency emergency stop stop Motor power Motor contactor xx1600000250 Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 211 (since the external emergency stop would not stop the robot). IRC5 Safety PROFINET/PROFIsafe controller Local Robot emergency Panel stop board 24 V External Motor power emergency stop Motor contactor Protective stop xx1600000251 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 212: Safemove Geometry Configuration File

    Stand Still Supervision • Axis Speed Supervision • Axis Position Supervision • Tool Orientation Supervision • External Power Supply Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 213 10 Reference information 10.5.1 Introduction Continued • Cyclic Brake Check • Stop Configuration Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 214: Use Cases

    2 Use Visual SafeMove to read the safety configuration from the robot controller. 3 Export the configuration to a SafeMove geometry configuration file. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 215 4 Import the SafeMove geometry configuration file into the external planning tool so that the nominal safety zones are updated with the values from the real robot. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 216: Explanation Of The Configuration File

    The template file SimplifiedSafetyControllerSchema.xsd can be obtained from the PC or the robot controller. • In the RobotWare installation folder in RobotStudio: ...\RobotPackages\ RobotWare_RPK_<version>\utility\SafeMove2\ Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 217 Navigate to the RobotWare installation folder from the RobotStudio Add-Ins tab, by right-clicking on the installed RobotWare version in the Add-Ins browser and selecting Open Package Folder. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 218: Drive Module Configuration

    The driveModuleId tag contains the ID of the motion task. Each motion task must have a unique ID between 1 and 4. The ID is not visible to the user. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 219: Robot Data

    Tool Position Supervision. The shapes should include the upper arm of the robot including any cable packages or additional arm-mounted equipment. The Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 220 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 221: External Axis

    The axisType tag must be Track for a track motion. Base frame The Baseframe tag specifies the position and orientation of the track motion. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 222: Tool

    A rounded box is generated by letting the center point of the generating sphere travel along a plane. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 223 10 Reference information 10.5.3.5 Tool Continued The below figure shows an example of a tool encapsulation with an ABB FlexGun covered by a capsule and a rounded box. xx1700000706 Limitations of the tool shapes The radius of any tool shape must be at least 50 mm. The distance between the two end points of the generating line of a capsule must be at least 50 mm.
  • Page 224 TCP and tool orientation The TCP and ToolOrientation tags defines the TCP and orientation of the current tooldata and must be specified. Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 225: Safe Zones

    The interior, high speed zones, ensure high robot productivity and low cycle times. Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 226 A corner of a zone must have an angle between 30 and 330 degrees. The below illustration shows the constraints that must be met by any zone definition. xx1700000704 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 227: Example

    <Start x="-0.268245" y="-0.017373" z="0.190867" /> <End x="1.03026" y="-0.096637" z="0.167713" /> </UpperArmGeometry> <UpperArmGeometry xs:type="Sphere" name="HosePackage" radius="0.5"> <Center x="-0.084216" y="-0" z="0.305324" /> Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 228 <Point x="-0.430474" y="2.750736" /> <Point x="-0.359415" y="-0.735027" /> <Point x="8.319961" y="-0.790136" /> <Point x="8.181677" y="2.193857" /> <Point x="6.422987" y="2.805629" /> Continues on next page Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 229 <Point x="5.035686" y="4.224637" /> <Point x="5.101747" y="5.381664" /> <Point x="5.023219" y="5.600441" /> <Point x="4.195253" y="5.658945" /> <Point x="3.479269" y="5.592942" /> </SafeZone> </DriveModuleConfiguration> </SimplifiedSafetyConfiguration> Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 230: How To Establish Cip Safety Communication With A Plc

    Currently, the Logix Designer tool does not support parsing of Safety EDS files. Therefore the user cannot import the EDS file of the ABB CIP Safety adapter and use it for CIP Safety applications. The only way to establish CIP Safety communication with the ABB adapter is to use the generic profiles present in Logix Designer.
  • Page 231 10 Reference information 10.6.1 Introduction Continued Parameter Setting Configuration Module parameters Parameter Setting Vendor Device type (product type) Product code Revision (major/minor) 2/50 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.

  • Page 232: Configuring The Abb Cip Safety Adapter In Studio 5000

    4 Click the Create button. A new Module Properties window appears, allowing for configuring of a new Ethernet/IP module. Configuring the general properties Use this procedure to configure the general properties of the ABB CIP Safety module. 1 Go to the General tab.
  • Page 233 11 If configuration signature shall be used, open the Safety tab of the Module Properties window to configure the Configuration Signature settings. Enter the ID, Date, and Time fields with the values obtained from the ABB safety report. Make sure to set the Time milliseconds field to 0 since the robot time only contains whole seconds.
  • Page 234 This page is intentionally left blank...

  • Page 235: Index

    17, 32 description, 42 SafetyControllerGetChecksum, 195 SafetyControllerGetOpModePinCode, 195 SafetyControllerGetSWVersion, 195 include safety settings, 186 SafetyControllerGetUserChecksum, 195 independent joint, 30 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 236 42, 197, 199 work area for additional axes, 29 sync switch, 58 world coordinate system changed, 192 system integrator requirements, 15 write configuration, 171 Application manual - Functional safety and SafeMove2 3HAC052610-001 Revision: P © Copyright 2016-2020 ABB. All rights reserved.
  • Page 238 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2016-2020 ABB. All rights reserved. Specifications subject to change without notice.

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