ABB S4Cplus User manual

Control Cabinet
S4Cplus
503 623-102
2001-05-18
ABB Flexible Automation AB
Welding Systems

The information in this document is subject to alteration without prior notice and should not be
regarded as an undertaking from ABB Flexible Automation AB. ABB Flexible Automation AB takes no
responsibility for errors that can occur in this document.
ABB Flexible Automation AB is not responsible for damage incurred due to the misuse of this
document, software or hardware described in this document.
The document, or parts of it, may not be reproduced or copied without prior permission from ABB
Flexible Automation AB. It may neither be imparted to a third party nor otherwise be used without
authorisation. Infringement hereof will be subject to action in accordance with applicable laws.
Further copies of this document can be obtained from ABB Flexible Automation AB at current prices.
© ABB Flexible Automation AB
Article number: 503 623-102
Date:2000-09-12
ABB Flexible Automation AB
Welding Systems
S-695 82 Laxå
Sweden.

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TABLE OF CONTENTS Page
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1 General......................................................................................................................... 5
1.1 Types of robot .................................................................................................... 5
2 Description top cabinet 620/820................................................................................. 7
2.1 Structure............................................................................................................. 7
2.1.1 Connections........................................................................................... 8
2.1.2 Option Extended emergency stop function ........................................... 9
2.1.3 Customer connections............................................................................ 9
2.1.4 Option swing frame............................................................................... 10
2.1.5 Safety/Directives and Standards............................................................ 10
2.1.6 Safety categories.................................................................................... 11
3 Technical Data ............................................................................................................. 13
4 Installation and set-up ................................................................................................ 15
4.1 Lifting instructions............................................................................................. 15
4.2 Mechanical installation...................................................................................... 15
4.3 Connections ....................................................................................................... 17
4.4 Start up............................................................................................................... 17
5 Maintenance................................................................................................................. 19
6 Reservdelsförteckning/Spare Parts List..................................................................... 21

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General
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1 General
1.1 Types of robot
The top cabinet for equipment from the standard product range is adapted for
connection to the control system S4Cplus. Please refer to the Product and User
Guide for a description of the control system.
The product range has been designed for the robot models IRB 140/1400/2400 in
the AW-design. However, some products can be fitted without modification to
other robot models.
Information regarding the combination options for respective products can be
found on product specifications.

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General
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503 623-102
Description top cabinet 620/820
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2 Description top cabinet 620/820
2.1 Structure
The Control Cabinet consists of the following units:
• Control system S4Cplus
• Top cabinet with interfaces for:
- positioner
- process equipment
- personal safety equipment
• Power source ARCITEC LRB (if applicable)
Cabinet_S4Cplus_8
T
op cabinet
6
20mm/820mm
C
ontrol system
S
4Cplus
P
ower source
L
RB
Programming unit

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Description top cabinet 620/820
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2.1.1 Connections
The interface modules in the top cabinet are connected to the control system via a
signal interface that distributes the requisite system signals and feeds. Connections
to the different units are made using jackable terminals to facilitate service and
repair work.
Inside the top cabinet with component interface modules.
Figure 1 Cabinet_S4Cplus_5
Cabinet_S4Cplus-7
Connection
Travel Track
Connection
positioner
Connection
Operator
panel
Connection
Safety
equipment
Connection
Process
equipment
Connection
External
welding power
source
Cabinet_S4Cplus-5
C
ustomer
c
onnections
P
ositioner
i
nterface
Option
Extended
Process
interface
emergency
OpCom
interface
Stop
Function

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Description top cabinet 620/820
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Figure 2 1 Extra customer space in top cabinet 820mm
2.1.2 Option Extended emergency stop function
Some installations require more emergency stop signals from the control system
than are available in the standard design. This applies, for example, when
emergency stop functions are required to be integrated in fixture control or
distributed to external equipment. This option offers a possibility of connecting an
optional number of redundant relays as required. See Figure 1
2.1.3 Customer connections
As standard the following signals and feeds are available on jackable terminals to
allow the addition of customer specific equipment :
Terminal A204-X1 24V I/O (DC) max 2A
Terminal A204-X2 Contactor/relay control via “MOTORS ON”
Two channel function control
Terminal A204-X3 Two channel connection for emergency stop device
Terminal A204-X4 CAN-bus connection
If the “Extended emergency stop” option is included the following signals are also
available:
Terminal A204-X5 Two channel contactor/relay control via “EMSTOP”
Two channel function control of contactor/relay control
as above
See Figure 1 for customer connections.
1
1
1

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Description top cabinet 620/820
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2.1.4 Option swing frame
A swing frame is available as an accessory to top cabinet 620/820. The swing frame
is fitted to the left-hand end of the top cabinet door opening. On the inside of the
swing frame space is provided for the installation of further equipment and
components.
1 Frame section
2 Lock
3 Transport lock
2.1.5 Safety/Directives and Standards
Electrical equipment is designed to comply with the demands set out in:
• EU's low voltage directive 72/23/EEC
• EU's EMC directive 89/336/EEC
And applicable parts of occupational health and safety related parts of EU's
Machinery directive 89/392/EEC.
The following standards:
• EN292-1 Safety of machinery. Basic concepts, general principles for
design. Part 1: Basic terminology, methodology
• EN292-2 Safety of machinery. Basic concepts, general principles for
design. Part 2: Technical principles and specifications
• EN418 Safety of machinery. Emergency stop equipment, functional
aspects. Principles for design.
32
1

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Description top cabinet 620/820
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• EN954-1 Safety of machinery. Safety related parts of control systems.
General principles for design.
• EN50199 Electromagnetic compability (EMC):Product standard for arc
welding equipment.
2.1.6 Safety categories
Equipment for personal safety has been designed so that safety functions are
maintained in the event of individual faults, such as a sticking relay, in the
supervision system. Faults are detected at the latest with the next call to the safety
function. This corresponds with category 4 in accordance with EN 954-1, Safety of
machinery. Safety related parts of control systems. Part 1: General principles for
design.
For other parts of the control system please refer to IRB 140/1400/2400.

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Description top cabinet 620/820
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Technical Data
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3 Technical Data
Also refer to the Product Manual for the robot
Weight 280kg (without power source)
380kg (with power source)
Additional (20)kg top cabinet
820mm
Additional 20kg swing frame
Additional 30kg power source with
transformer
Dimensions (WxHxD), top cabinet 820mm in brackets
800x1570(1770)x623mm (without power source)
800x2010(2210)x623mm (with power source)
Environmental demands
Transport temperature Min –25°C
Max +42°C
Max +70°C
Operating temperature (ambient) Min +5°C
Max +45°C
Relative humidity Max 95% at constant temperature
Electrical data (incl. control cabinet):
Mains voltage 3x200 – 600V AC, +10%,-15%
Frequency 48.5 – 61.Hz
Fuse protection 16A slow burn (400V)

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Technical Data
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The following applies for the control cabinet with power source LRB400:
1) 400V without power source transformer.
2) Fuse in brackets can be used if recommended fuse is unavailable.
Rated power (without/with ext. axes) 4.5/7.8kVA without power source
17.5/20.8kVA with power source
Protection class IP54
IP21 power source LRB400
Nätspänning/
Mains voltage
( V )
Säkring (Trög) /
Fuse (Slow-blow) 2)
( A )
200 80
220 80
1) 400 32 ( 35 )
440 40 ( 50 )
475 40 ( 35 )
500 32 ( 35 )
525 32 ( 35 )
600 32 ( 35 )

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Installation and set-up
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4 Installation and set-up
4.1 Lifting instructions
The control cabinet is fitted with lifting eyes to allow easy lifting.
Qualified personnel may only lift the control cabinet using equipment that
corresponds with applicable lifting standards.
4.2 Mechanical installation
The base of the control cabinet has fastening holes for secure mounting to the floor.
The surface should be flat and solid corresponding to a concrete, workshop floor.
Holes for expansion bolts or the like should correspond with the hole pattern
illustrated below.
lifting instructions
min 60 degrees

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Installation and set-up
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Also refer to the Product Manual for the robot.
The control cabinet is supplied mounted on a stand in welding cells type FlexArc
Compact. In this design the bottom section of the control cabinet is bolted directly
to the stand.
400mm
720mm
a
a
a
a = clearance min 250mm
S4C-plus top

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Installation and set-up
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4.3 Connections
Mains connection
The control cabinet is supplied as standard with cable glands for the entry of
incoming supply cables. The mains voltage is connected to the control cabinet’s
main power switch as set out in the wiring diagram.
The main connection must be carried out by qualified personnel.
Also refer to the Product Manual for the robot.
In welding cells type FlexArc and FlexArc Compact the mains cable is routed to a
63A IEC-socket, located on the wall of the cell, for easy mains connection.
Information on the mains voltage, fuse protection, etc can be found in section 3
“Technical data”.
4.4 Start up
Check that all component equipment is connected correctly.
Switch on the main power switch on the control cabinet and the main power switch
on the welding power source if fitted. The main power switch on the control
cabinet normally controls the power supply to all component modules in the
cabinet.
Note! Some welding power sources provide the process control card with
external reference voltage, which is why parts of the control cabinet can be
energised even when the main power switch is in the “OFF” position.
All requisite system software is installed on delivery.
Wait until the message “Welcome to….” is shown on the programming unit’s
display.
Control cabinet_S4Cplus-7

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Installation and set-up
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The system is now ready for use.

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Maintenance
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5 Maintenance
Clean any filters according to the instructions in the robot’s Product Manual and in
the product Manual for the power source.
Check that the cables/connectors are not damaged. Damaged components must be
replaced immediately.
If personnel safety equipment has been included this should be tested preferably in
connection with each new shift.

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Maintenance
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