ABB FlexLoader SC 3000 Operating Manual
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ABB FlexLoader SC 3000 Operating Manual

ABB FlexLoader SC 3000 Operating Manual

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ROBOTICS
Operating Manual
FlexLoader SC 3000

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Summary of Contents for ABB FlexLoader SC 3000

  • Page 1 ROBOTICS Operating Manual FlexLoader SC 3000...
  • Page 2 Trace back information: Workspace Robots and Applications version a98 (not checked in) Published 2025-05-19 at 11:54:47 Skribenta version 5.6.019...
  • Page 3 Operating Manual FlexLoader SC 3000 Document ID: 4GAA138009903-001 Revision: A © Copyright 2025 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

    Table of contents Table of contents Overview of this manual ........................License agreement for FlexLoader SC 3000 ................... Getting Started Safety Introduction ...................... Safety during installation, commissioning and decommissioning ........ Safety during setup, maintenance, service and repair ..........Cyber Security ....................
  • Page 6 Standard 3-finger gripper (IRB 2600) ............Status ......................6.9.1 Light beacon ..................6.9.2 SCADA ....................Safety functions Supervision functions ..................7.1.1 FlexLoader SC 3000 Open Front ..............Additional functions ................... 7.2.1 Synchronization ..................7.2.2 CBC ...................... Backup and Restore FlexLoader Vision ..................... 8.1.1 Backup FlexLoader Vision ................

  • Page 7: Overview Of This Manual

    Overview of this manual Overview of this manual About this manual The FlexLoader SC 3000 is an automation solution used for machine tool tending. This manual contains instructions for operation of FlexLoader SC 3000. Usage This manual should be used during: •...
  • Page 8 Product manual - IRB 1600 3HAC026660-001 Product manual - IRB 2600 3HAC035504-001 Product manual - FlexLoader SC 3000 4GAA137009901-001 Installation and Commissioning manual - FlexLoader SC 3000 4GAA136009915-001 Operating manual – IRC5 with FlexPendant 3HAC050941-001 Operating manual – Troubleshooting IRC5 3HAC020738-001...

  • Page 9: License Agreement For Flexloader Sc 3000

    License agreement for FlexLoader SC 3000 License agreement for FlexLoader SC 3000 1 ABB is the only owner of the copyright and usage rights of the FlexLoader SC 3000 software option that is delivered. 2 ABB assigns the license a simple, non-transferable, exclusive, but unlimited right to use the FlexLoader SC 3000 software option.
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  • Page 11: Getting Started

    Follow the steps below for getting started with a FlexLoader SC 3000. Action Become familiar with this manual. Transport the FlexLoader SC 3000 to its intended location and integrate it with machine tool(s) and other equipment. Pay special attention to safety and functional interface.
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  • Page 13: Safety

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

  • Page 14: Safety During Installation, Commissioning And Decommissioning

    WARNING Maintain established good work practices with regard to robot safety. Ensure that nobody is within the safeguarded area during automatic operation. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 15: Safety During Setup, Maintenance, Service And Repair

    Prior to commencing work on the FlexLoader SC 3000, it is essential to conduct the following checks. •...
  • Page 16 2.3 Safety during setup, maintenance, service and repair Continued CAUTION Safety shoes shall be used when working with the FlexLoader SC 3000. The need will depend on the application and shall be risk assessed. CAUTION Pneumatic energy can be stored in the gripper system. Be aware of crushing risk.

  • Page 17: Cyber Security

    ABB Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage, and/or theft of data or information.

  • Page 18: Limitation Of Liability

    Overview Any information given in this manual regarding safety must not be constructed as a warranty by ABB that the FlexLoader SC 3000 will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.

  • Page 19: Nation And Region Specific Regulations

    To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the FlexLoader SC 3000 is installed. Within the EU, refer to the Machinery Directive 2006/42/EC with addendum.

  • Page 20: To Be Observed By The Supplier Of The Complete System

    2.7 To be observed by the supplier of the complete system Overview The integrator is responsible for making sure that the safety devices necessary to protect people working with the FlexLoader SC 3000 are designed and installed correctly. When integrating the FlexLoader SC 3000 with external devices and machines: •...

  • Page 21: Safety Signals In The Manual

    Signal word used to indicate important facts and NOTE conditions. Signal word used to indicate where to find additional information or how to do an operation in an easier way. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 22: Installation And Operating Safety

    Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 23: Residual Risks

    Risks are associated with control failure due to poor programming or a calibration error. • Risk of entrapment/crushing of fingers between gripper finger and workpiece. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
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  • Page 25: Product Description

    Safety on page 13 and to be familiar with the safety devices. The FlexLoader SC 3000 is an automation solution used to feed workpiece to a robot for processing by one or two machine tools and optional post-processing equipment. The FlexLoader SC 3000 is a pre-engineered, well-proven and reliable solution, suitable for different types and sizes of workpiece.
  • Page 26 3 Product description Continued Main features The following main features are included in the FlexLoader SC 3000: • ABB industrial robot with SafeMove Pro • Integrated robot controller and electrical equipment • FlexLoader Vision and associated illumination • Conveyor feeding system •...

  • Page 27: Flexloader Sc 3000 Twin

    3 Product description 3.1 FlexLoader SC 3000 Twin 3.1 FlexLoader SC 3000 Twin Introduction The FlexLoader SC 3000 Twin with conveyors consists of the following main parts. Figure 3.1: FlexLoader SC 3000 Twin - Overview Pos. Component Electrical cabinet with operator panel front and main switch...
  • Page 28 3 Product description 3.1 FlexLoader SC 3000 Twin Continued Figure 3.2: FlexLoader SC 3000 Twin - Overview Pos. Component Rear door Operator panel (rear) Robot Standard gripper (option) Left door posts Illumination with camera Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A ©...
  • Page 29 Machine 2 Note FlexLoader SC 3000 Twin has two door openings, one on each side. Each door can be configured as a cover plate, a door, or a door with posts. As per the above figure, the rear door can be used for entry after the integrator makes a mechanical adjustment.

  • Page 30: Flexloader Sc 3000 Open Front

    3 Product description 3.2 FlexLoader SC 3000 Open Front 3.2 FlexLoader SC 3000 Open Front Introduction The FlexLoader SC 3000 Open Front with conveyors consists of the following main parts. Figure 3.4: FlexLoader SC 3000 Open Front - Overview Pos.
  • Page 31 3 Product description 3.2 FlexLoader SC 3000 Open Front Continued Figure 3.5: FlexLoader SC 3000 Open Front - Overview Pos. Component Operator panel (rear) for Emergency stop Robot Standard gripper (option) Safety laser scanner Illumination with camera Continues on next page...
  • Page 32 3 Product description 3.2 FlexLoader SC 3000 Open Front Continued Naming conventions The figure below shows the naming conventions used in the FlexLoader SC 3000 Open Front. Figure 3.6: FlexLoader SC 3000 Open Front naming conventions Pos. Description Side cover...

  • Page 33: Operator Interface

    3.3 Operator interface 3.3 Operator interface Operator panel interface Devices for controlling the robot and the safety system are found at the front and back panels of the FlexLoader SC 3000. Operator panel - front Figure 3.7: Operator panel (front) Pos.
  • Page 34 Request cell entry Reset entry Operator panel - Rear (Open Front) The FlexLoader SC 3000 Open Front has only an emergency stop button on the rear side panel. Figure 3.9: Operator panel - Rear (Open Front) Continues on next page...
  • Page 35 FlexLoader vision interface This interface is used to start and end new processes, modify programs, and check system status. Figure 3.10: FlexLoader Vision interface Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
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  • Page 37: Navigating Flexloader Vision

    4 Navigating FlexLoader Vision 4.1 FlexLoader Vision Introduction FlexLoader Vision is a vision system that guides ABB industrial robots when handling materials. It is a proven system offering high speed, short teach-in times, reliable production and a user-friendly interface. ABB offers software that identifies the workpiece location and orientation from the picking area and guides the robot with precision in the robot cell.

  • Page 38: Menu

    Used to display safety information. Needs to be configured. SCADA Used to display cell information. Alarm List Displays active/unconfirmed alarms. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 39 Used to changing the brush size for tool Pen and Eraser. The brush size is displayed as a ring and the size can also be adjusted with the mouse scroll wheel. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 40: Operation

    Button for start of production Stop production Button for stop of production Part selection Lists to select part for start of production Result Displays results of images Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 41: Teachin

    A part must always be selected to be able to enter different tabs. Part selection Selection for part to adjust teach-in Settings Settings for part Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 42 Panel with settings for current tab. Differ between tabs. Navigation Buttons for navigating TeachIn. Click on arrow down for more buttons options such as Cancel, Save as and so on. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 43: Lite

    Part selection Selection for part to adjust teach-in for Lite product. Settings Setting for current part. Navigation Buttons for navigating teach-in of Lite product. buttons Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 44: Camera

    Displays Live image from camera. Allows user to test light settings for camera. Calibration Handles calibration of camera and robot connection. Settings Handles settings for camera placement. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 45: Settings

    The Gripping Limitations can be used to define an unlimited number of limitations for the system. These limitations can be Limitations applied during the teach-in process of a detail. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 46 Tool organizer Allows to rename, move and delete tools in the database by using the buttons to the right. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 47 Vision is configured. In the example below, FlexLoader Vision is configured towards SC 3000 Twin. For the SC 3000 the Mechanics tab displays the current status of signals of the conveyor. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 48 Allows to handle restart and shutdown of the computer. handling Robot Used to configure the IP-address to the connected robot. configuration Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 49 Allows user to add or delete existing limitations Limitation Settings box for current selected limitation settings Limitation guide Explanation over what is displayed in camera view Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 50: Safety

    The Safety window is very similar to the SCADA window. By default, the Safety is not enabled but can be configured by the integrator. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 51: Scada

    Integrators can configure the graphical appearance and select which data to show. The configuration can contain multiple tabs, which all can be configured by the integrator. Below is an example of the preconfigured SCADA for FlexLoader SC 3000 Twin. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A...
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  • Page 53: Teachin

    No robot programming is needed. The program is created by entering the shape and size of the part and the machine fixture. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 54: Create Part

    To rename a detail, select the detail, click Rename and specify a new name. 1 Select a part type for the Raw Part and Finished Part. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 55 Height: Total height of part. Weight: Weight of part in kilograms. • For Round part, enter: A: Diameter of part Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 56 For Square, enter: A: Width of part Radius: Radius of corner of part. If the part has sharp corners, enter Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 57 A: Width of part B: Length of part Radius: Radius of corner of part. If the part has sharp corners, enter Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 58 For Hexagon part, enter: A: Width of part 3 Repeat step 2 for Finished part. 4 When all values have been entered, click Next. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 59: Load

    The robot exits the machine and machine cycle starts. • Normal mode: If the option above is not activated the normal mode is used. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 60 6 Enter the dimensions of the machine workpiece holding. A: The height of the jaws. The distance is entered from where the work object is placed. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 61 The Unload part only should be activated if a bar feeder is used for the lathe. This option will hide the rest of the settings on the Load page. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 62 By using this option, the robot will press the part against the workpiece holding with the spring to help the machine self-center the part during loading. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 63 D: A value that is available for the sub spindle. The sub spindle often has an option to offset the spindle. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 64 The X and Y direction will offset according to the placement of the work objects. As a standard they are placed as the figure below: 8 Select Next when all load settings have been entered. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 65: Unload

    2 The option Stack finished parts allows parts to be stacked at the outbound conveyor. Activate the option and enter how many parts that should be placed in each stack. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 66 C: Grip height for the finished part. E: The width of where the finished part is gripped. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 67 3 The option Stack finished parts allows parts to be stacked at the outbound conveyor. Activate the option and enter how many parts should be placed in each stack. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 68 If this option is selected, the configure button becomes available. In the pop-up window, enter the dimensions for the scrap part. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 69 X-Y: The X and Y values are offsets which can be used of the part is not to be loaded into the center of the chuck or if the part is not gripped in the center Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 70 As a standard they should be placed as the figure below: 9 Click Save when all unload parameters have been filled in. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 71: Test Run

    The question will show each time at the beginning of all unvalidated scenarios. CAUTION Select validate only after you have completely tested the scenario and confirmed that it works correctly. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 72: Customizable Teach-In

    Lite program. For customizable the teach-in, the operator set how the part is located under the camera and adjust the robot RAPID program to suit the specific part. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 73: Detail

    1 Locate the teach-in in the correct group in the list to the left. 2 Click to highlight selected teach-in. 3 Double-click on teach-in or select Edit to the right of the list. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 74 The Wizard will provide extra help throughout the teach-in process. A help text will show at each of the different tabs, giving an explanation to which steps need to be taken for that specific tab. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 75: Image

    The results can differ widely depending on the order in which the filters are applied. This gives a large number of possible combinations. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 76 Dilate Increases the size of the light areas by adding a small area along the entire edge. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 77 TRUE. FlexLoader Vision will reset the filter and set the value of the bool bResetPickedCam1 to FALSE when the command is complete. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 78: Positions

    2 With the cursor, click and drag the area of interest around the part of the image that should be used for this position. Usually, the area of interest is the entire part. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 79 The settings are accessed by clicking on the Advanced button in the Positions tab. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 80 The effect of changing the settings is updated continuously in the image. Note The Smoothness settings affect every position on teach-in. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 81: Parameters

    When the Pen tool is selected it is possible to erase by drawing with the right click on the mouse. 6 Use the Clear button to remove all masking. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 82 It is generally recommended to search for more than one part, in case the identified part is not pickable. A recommended start number is 4 parts. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 83 Score target. Image from teach-in Current image with extra edges Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 84 The Separation sets how close the found parts are allowed to be. The distance can be set in x- or y-coordinates, in scale factor or in rotation angle. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 85: Tool

    B = Width of finger C = Depth of finger D = Rotation of TCP 3 Select Next to continue to next page. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 86 3 Enter the Width and Height of the grid for creating a tool. The TCP will be in the center of the grid. 4 Select OK. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 87 The X-direction of the TCP is to the right in image. 8 Select Save to save the tool. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 88: Grip

    The Positioning height is the Z-value of the position where the robot will move to before entering the pick position Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 89 The Grip height specifies the Z-value of the pick position. 8 Click Next to continue to next page. Press the icon to open an explanation of the grip settings. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 90 Setting to sort which of the found parts that will get prioritized to send to the robot. Limitations Activate grip limitations for current teach-in. The Grip Limitations needs to be created from the Settings page. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 91: Supervision

    Adjust the Threshold or check the setting for dirt suppression, see Advanced Image supervision on page Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 92 If Allowed overlap is activated, the gripper is allowed to collide with objects in the image to a certain extent. The value is specified in square millimeters. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 93 If only the Detail supervision is active, only parts that are located will be used for the collision supervision. With the Secondary search more parts are allowed to be found. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 94 G Activate and adjust the Gripper out-of-image control, if necessary. H Activate and adjust the Allowed overlap, if necessary. Select OK to closed Advanced window. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 95 F Use the Eraser tool in the Tool Box to the right to erase the supervision. G Use the Clear button to remove all supervision. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 96 F Use the Eraser tool in the Tool Box to the right to erase the masking. G Use the Clear button to remove all masking. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 97 Image before suggest Image after suggest Adjust the Advanced settings, if necessary. J Deactivate the box Edit. 5 Click Next to continue to next page. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 98: Mechanics

    The Mechanics tab is used to control the mechanic units in the system. The tab will differ depending on the configuration. Below is an explanation of the mechanical tab for the FlexLoader SC 3000 Twin. Robot program During the start and stop of the production, the robot module containing all logic and positioning for the current part gets loaded into the robot system.
  • Page 99 The Default values button will reset all values to their default values. The Update PLC button will force send all settings immediately to the PLC. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 100: Test And Save

    Press one result in the list to highlight that part in the image window. With the Image supervision available, every unknown object that is considered for the collision supervision is displayed in green. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 101 A tool collision would occur if the detail were to be picked. If multiple positions are active, they will display as the image below. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 102 Next button. The options to Save, Save As and Save Continue are available. The Save and Save as will save and exit the teach-in. The Save Continue will save without exit. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 103: Rapid

    Search for !TODO in the RAPID module PartCam1 to find the major places where the template needs to be adjusted. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 104 5 Teachin 5.2.10 RAPID Continued Below is a description of the basic steps of the template. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 105: Operation

    6.1 Power 6.1.1 Power ON the FlexLoader SC 3000 Follow the steps below to Power ON the FlexLoader SC 3000: 1 Turn ON the main switch. Wait until all devices have started up. 2 Perform a power on start-up test: •...

  • Page 106: Power Off The Flexloader Sc 3000

    6.1.2 Power OFF the FlexLoader SC 3000 6.1.2 Power OFF the FlexLoader SC 3000 Follow the steps below to Power OFF the FlexLoader SC 3000: 1 Stop FlexLoader SC 3000 and await a complete cycle stop. 2 Exit the FlexLoader Vision application.

  • Page 107: Start

    7 Click Start in the FlexLoader Vision user interface. The selected robot program for the detail will now be loaded in the robot and the FlexLoader SC 3000 will start. 8 Answer start-up questions on the FlexPendant.

  • Page 108: Restart Cycle

    2 Reset all safety. 3 Ensure robot is in automatic mode. 4 Press the black start button to start the robot program. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 109: Restart Cycle After A Non-Controlled Stop

    5 On the FlexPendant, open the production window and select Move PP to Main. 6 Press the black start button to restart the robot program. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 110: Stop

    2 Click Stop. A message will display on the screen to indicate that the stop is pending. 3 Wait for the system to stop. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 111: Cycle Stop

    2 Wait for system to stop. The button will turn solid green when the stop is complete. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 112: Robot Stop

    2 Wait for robot to stop. Note The robot stop is not an emergency stop. In the case of an emergency, the emergency stop should always be used. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 113: Empty Cell

    4 Wait for the emptying cycle to complete. The button will change status to Emptying of cell in progress while the emptying request is started. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 114: Safety Stop

    Note The emergency stop buttons must only be used in emergency situations. Do not use emergency stop buttons to stop FlexLoader SC 3000 in normal operation. WARNING Note that grippers and other pneumatic equipment may contain stored pneumatic energy when the emergency stop is active.

  • Page 115: Reset Emergency Stop

    6.4.2 Reset Emergency Stop 6.4.2 Reset Emergency Stop WARNING Ensure that a restart of FlexLoader SC 3000 does not cause any risks of damage to equipment or personal injury before reset of emergency stop. To reset the emergency stop, follow the steps below: 1 Release all activated emergency stop buttons.

  • Page 116: Reset Protective Stop

    6.4.3 Reset Protective Stop 6.4.3 Reset Protective Stop To reset the protective stop, follow the steps below: 1 Close all the doors of FlexLoader SC 3000 or exit the safety scanner protective stop zone. 2 Restore all external protective stops.

  • Page 117: Manual Operation

    6.5 Manual Operation 6.5.1 Run in manual mode FlexLoader SC 3000 can be run in manual mode with the mode manual with reduced speed on the robot. When the robot communicates with FlexLoader Vision, the operator needs to grant written access to FlexLoader Vision.

  • Page 118: Gripper

    - : This symbol can display if the gripper is in an unknown status. This is usually displayed after a warm start of the robot. When a gripper in this status is toggled, the gripper will close. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 119: Vision Light

    To manually turn on or off the vision light, use the FlexPendant programmable button 2. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 120: Parttracker

    6.6 PartTracker General The PartTracker is used by the FlexLoader SC 3000 to keep track of the status of the parts and where they are placed. If a part has manually been removed the PartTracker needs to be updated. The PartTracker menu will open on the FlexPendant operator window.
  • Page 121 Station for machine 2. Used for sub spindle if machine 2 is sdMachine2Sub configured as a lathe. Not available for FlexLoader SC 3000. sdMachine Station for robot gripper 1 sdRobot_Gripper1 Station for robot gripper 2 sdRobot_Gripper2 Not available for FlexLoader SC 3000.
  • Page 122 3. The PartTracker menu will open when the robot is finished with the current cycle. 2 Select which station to edit. 3 Select action Move. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 123 3. The PartTracker menu will open when the robot is finished with the current cycle. 2 Select which station to edit. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 124 3. The PartTracker menu will open when the robot is finished with the current cycle. 2 Select which station to edit. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 125 6 Operation 6.6 PartTracker Continued 3 Select action Edit. 4 Select which element to edit and press OK. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 126 OK. Enter the text and select OK. 5 When the station has been edited, select PartState and press return. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 127 The tracker data will always be created when a raw part is pick from the conveyor. Exit PartTracker menu To exit the PartTracker menu, use the Back button. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 128: Conveyor

    The conveyor will be moved stepwise so that the robot can fill up the entire belt during production. The manual operation is done from the SCADA-view called Feeder Control in FlexLoader Vision. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 129: Inbound Conveyor

    AUTO. Note Do not forget to switch the mode back to automatic to allow the robot to control the conveyor. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 130 WARNING The conveyor will not stop automatically while moving the belt backwards. Be careful about parts falling down from the conveyor and cause injury. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 131: Outbound Conveyor

    The outbound conveyor will stay in emptying mode and continue to move the belt outward when the sensor is not affected until the operator switches the mode back by pressing the Emptying button . Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 132: Gripper Settings

    6.8 Gripper Settings General The standard grippers available for FlexLoader SC 3000 are delivered with gripper jaws, which make it possible to adjust the position of the gripper fingers on the gripper. The jaws are labelled with numbers that are used for reference for the gripper finger setting.

  • Page 133: Standard 2-Finger Gripper (Irb 1600 And Irb 2600)

    Holes for guide pin for flexible finger 5 Mount the fingertip back to the base. 6 Attach the shoulder screw. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 134 Changing gripper inserts The standard 2-finger gripper for FlexLoader SC 3000 is delivered with five different types of inserts for the grippers to cover a wide variety of parts and gripping surfaces.
  • Page 135 FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 136 FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 137: Standard 3-Finger Gripper (Irb 1600)

    FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 138 FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 139: Standard 3-Finger Gripper (Irb 2600)

    FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 140 FlexLoader Vision Lite uses the values in the table above when informing the user regarding the recommended finger settings based on the parameters that have been filled in for the teach-in. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 141: Status

    Green The robot program is running FlexLoader SC 3000 Twin The FlexLoader SC 3000 Twin has integrated RGB lights on both sides of the roof, as shown in the figure below. Figure 6.1: FlexLoader SC 3000 Twin Continues on next page...
  • Page 142 Continued FlexLoader SC 3000 Open Front The FlexLoader SC 3000 Open Front has integrated RGB lights on both sides of the roof and also on the side panel, as shown in the figure below. Figure 6.2: FlexLoader SC 3000 Open Front...

  • Page 143: Scada

    Button to start emptying process. See section Empty cell on page 113. Navigation buttons to respective tabs in SCADA. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 144 Overview on page 128. Safety tab – FlexLoader Vision SC 3000 Twin. The Safety tab gives the operator a more detailed status of the safety. Safety tab for FlexLoader SC 3000 Twin is shown in the figure below. Pos. Description Clock...
  • Page 145 Current door is closed Safety tab – FlexLoader Vision SC 3000 Open Front The Safety tab gives the operator a more detailed status of the safety. Safety tab for FlexLoader SC 3000 Open Front is shown in the figure below. Pos. Description...
  • Page 146 This page is intentionally left blank...

  • Page 147: Safety Functions

    7 Safety functions 7.1.1 FlexLoader SC 3000 Open Front 7 Safety functions 7.1 Supervision functions 7.1.1 FlexLoader SC 3000 Open Front Safety Scanner Template The safety laser scanner consists of three zones. The first zone is monitored by the PLUTO Safety PLC, the second zone is monitored by SafeMove, and the third zone is monitored by the RAPID program.
  • Page 148 7 Safety functions 7.1.1 FlexLoader SC 3000 Open Front Continued Protective Stop zone The Protective Stop zone main purpose is to protect the operator from the external machine. During the installation, it is necessary to ensure that this zone is configured correctly.

  • Page 149: Additional Functions

    7.2 Additional functions 7.2.1 Synchronization General By default, the FlexLoader SC 3000 uses software synchronization for the safety controller. A synchronization may need to be done if: • If one or more axes were moved during shutdown or power off.
  • Page 150 Synchronization position - Twin The default position for the synchronization is with the robot at axis position 20,0,0,0,0,0. The robot should be parallel to the FlexLoader SC 3000 base. When performing the synchronization, move the robot to the position and perform a visual check that the robot is in the correct position.
  • Page 151 Synchronization position - Open Front The default position for the synchronization is with the robot at axis position -40,0,0,0,0,0. The robot should be parallel to the FlexLoader SC 3000 base. When performing the synchronization, move the robot to the position and perform a visual check that the robot is in the correct position.

  • Page 152: Cbc

    6 hours. It normally runs automatically during the initialization when a new job starts or during each cycle during the procedure CheckSystem. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 153: Backup And Restore

    It is a good practice to store your backups on multiple location to reduce the risk for data loss if one of the locations becomes corrupt. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 154: Flexloader Vision

    To create a backup of FlexLoader Vision, follow the steps below: 1 In FlexLoader Vision, go to the Settings page. 2 Go to the Service tab. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 155 A default directory for backups is located in the installation directory for FlexLoader Vision. The default Backup directory for FlexLoader Vision is located at: D:/Program Files/ABB Industrial IT/FlexLoader Vision/Backup Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 156 FlexLoader Vision will use the System Name of the FlexLoader Vision installation and the Date and Time when the backup was created to name the backup. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 157: Restore Flexloader Vision

    To restore FlexLoader Vision from a previous backup, follow the steps below. 1 In FlexLoader Vision, go to the Settings page. 2 Go to the Service tab. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 158 FlexLoader Vision from. Click OK to restore FlexLoader Vision from the selected backup. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 159 FlexLoader Vision properly. Click OK to shutdown FlexLoader Vision. 6 FlexLoader Vision has now been restored to the selected backup, and FlexLoader Vision can be started again. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 160: Robot

    To create a backup of the robot, follow the steps below. 1 Press the Menu button. 2 Press Backup and Restore. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 161 8.2.1 Backup Robot Continued 3 Press Backup Current System. 4 Press Backup to create a backup of the current robot system. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 162 … button, then use the On-Screen Keyboard to change the path. 5 The following screen will be shown during the creation of the backup. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 163: Restore Robot

    To restore the robot from a previous backup, follow the steps below. 1 Press the Menu button. 2 Press Backup and Restore. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 164 Continued 3 Press Restore System. 4 Press the ... button to select the backup folder you want to restore from. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 165 5 Browse to and select the backup folder from the system that should be restored. Press OK to confirm. 6 Press the Restore button to start the restore of the system. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 166 Press the Yes button to proceed with the restore of the system. 8 The restore process will now start, and the following screen will be shown. The robot controller will then restart. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 167: Troubleshooting

    MachineAction is not defined. Warning MachineCheck called with bad argument. gen_NoValidCheck Action type stated in call to MachineAction is not defined. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 168 {1}. Error Bad coordinates or offset - Camera {1}. flv_BadCoordinate Check returned vision values and camera calibration for camera {1}. Continues on next page Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.
  • Page 169 Movement from this zone to target zone is not allowed. Robot Information regarding alarms, warnings and information directly related to the robot can be found in the Troubleshooting IRC5 Manual. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 170: Problems With Accuracy

    For information regarding securing the unit and the robot to the floor, see Securing the unit section in Installation & Commissioning manual – FlexLoader SC 3000 • Continue troubleshooting by referring to see respective Robot manuals.

  • Page 171: Identification Problems

    • Redefine the masked surface. Try to find an identification surface of the present position that markedly differs from other positions. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 172: Communication Problems

    Messages about missing robot variables • Check if the named variable is defined in the robot. • Check the connection between the robot and FlexLoader Vision. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 173: Conveyor Problems

    When no parts are loaded on the conveyor: A belt that is tensioned too much can prevent the motor from moving. Loosen the tension on the belt a bit by loosening the adjustment screws carefully. Operating Manual - FlexLoader SC 3000 4GAA138009903-001 Revision: A © Copyright 2025 ABB. All rights reserved.

  • Page 174: Gripper Problems

    Note The standard grippers available for FlexLoader SC 3000 are developed to cover a wide variety of parts. For reference parts where the standard grippers are not suitable, special grippers or gripper fingers designed for those parts should be used.

  • Page 175: Index

    Empty cell, 113 Restore Robot, 163 Robot Stop, 112 FlexLoader SC 3000 Operator interface, 33 SafeMove, 168 FlexLoader SC 3000 Open Front, 30 safety FlexLoader SC 3000 Twin, 27 signals in manual, 21 Naming conventions, 29 symbols, 21 FlexLoader Vision, 37...
  • Page 178 ABB AB Robotics & Discrete Automation Robotics S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 abb.com/robotics © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.

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