ABB FlexLoader SC 6000 User manual

ROBOTICS
Product manual
FlexLoader SC 6000

Trace back information:
Workspace Robots and Applications version a61
Checked in 2020-03-06
Skribenta version 5.3.033

Product manual
FlexLoader SC 6000
R19D
Document ID: 3HAC051768-001
Revision: D
© Copyright 2014-2020 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2014-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
111 Getting started
132 Safety
132.1 Introduction ......................................................................................................
142.2 Safety during installation, commissioning and decommissioning ................................
152.3 Safety during setup, maintenance, service and repair ..............................................
172.4 SafeMove ........................................................................................................
192.5 Limitation of liability ...........................................................................................
202.6 Nation and region specific regulations ...................................................................
212.7 To be observed by the supplier of the complete system ............................................
232.8 Safety signals in the manual ................................................................................
253 Installation
253.1 General ...........................................................................................................
263.2 Mechanical installation .......................................................................................
433.3 Electrical installation ..........................................................................................
443.4 Pneumatic installation ........................................................................................
453.5 Robot gripper connections ..................................................................................
463.6 Machine tool installation .....................................................................................
483.7 Network connections .........................................................................................
543.8 Network security ...............................................................................................
553.9 Licensing .........................................................................................................
563.10 Moving the FlexLoader SC 6000 ...........................................................................
574 Commissioning
574.1 User accounts ..................................................................................................
584.2 Powering on the FlexLoader SC 6000 ....................................................................
594.3 Vision system FlexLoader Vision ..........................................................................
604.4 Robot system ...................................................................................................
604.4.1 Introduction ............................................................................................
614.4.2 Calibration of the coordinate systems .........................................................
724.4.3 Further integration steps ..........................................................................
734.5 Machine tool ....................................................................................................
744.6 SafeMove ........................................................................................................
764.7 Marking unit .....................................................................................................
774.8 Deburring/grinding unit .......................................................................................
795 Interface
795.1 Safety interface .................................................................................................
805.2 Function interface .............................................................................................
836 Function description
836.1 Overview .........................................................................................................
906.2 General function description ................................................................................
917 RAPID program
917.1 Overview .........................................................................................................
927.2 FlexLoader application functionality ......................................................................
1027.3 FlexLoader Vision interface .................................................................................
1047.4 FlexLoader Vision Lite functionality ......................................................................
1067.5 FlexLoader Library Add-in ...................................................................................
1127.6 FlexLoader assistance and utility functionality ........................................................
1157.7 FlexLoader machine tool interface functionality .......................................................
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1177.8 FlexLoader options functionality ..........................................................................
1187.9 WorldZones .....................................................................................................
1198 Operation
1198.1 Overview .........................................................................................................
1208.2 Powering on the FlexLoader SC 6000 ....................................................................
1218.3 Shutting down the FlexLoader SC 6000 .................................................................
1228.4 Operating FlexLoader SC 6000 with FlexLoader Vision .............................................
1248.5 Emergency stop ................................................................................................
1258.6 Entry control ....................................................................................................
1278.7 SafeMove operation ...........................................................................................
1298.8 Manual gripper control .......................................................................................
1308.9 Conveyor operations ..........................................................................................
1338.10 Indicator lamps .................................................................................................
1348.11 Statistical outlet ................................................................................................
1359 Maintenance
1359.1 Maintenance schedule .......................................................................................
1369.2 Mechanical maintenance ....................................................................................
1389.3 Electrical maintenance .......................................................................................
1399.4 Pneumatic maintenance .....................................................................................
1419.5 Backup ............................................................................................................
1429.6 Other maintenance ............................................................................................
14310 Repair
14310.1 Introduction ......................................................................................................
14410.2 Conveyors .......................................................................................................
14810.3 Illumination ......................................................................................................
14910.4 FlexLoader Vision .............................................................................................
15110.5 Standard gripper ...............................................................................................
15210.6 Re-grip table ....................................................................................................
15310.7 Turn station ......................................................................................................
15510.8 Air cleaning box (option) .....................................................................................
15710.9 Grinding/Deburring units (option) .........................................................................
16010.10 Air preparation units ..........................................................................................
16210.11 Marking unit .....................................................................................................
16310.12 Robot mounting/dismounting ...............................................................................
16410.13 Software ..........................................................................................................
16511 Troubleshooting
16511.1 Alarms, warnings and informations and troubleshooting ...........................................
16912 Decommissioning
16912.1 General ...........................................................................................................
17012.2 Environmental information ..................................................................................
17313 Spare parts
17514 Diagrams
177A Project specific parameters that can be adapted
179B Robot I/O
183C Internal communication
185D Pre-configuration settings
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187E Frequency inverter
193F FlexLoader RAPID reference
193F.1 FlexLoader data type prefix .................................................................................
194F.2 FlexLoader Vision interface .................................................................................
201F.3 FlexLoader application functionality ......................................................................
209F.4 FlexLoader Vision Lite functionality ......................................................................
210F.5 FlexLoader conveyor system control .....................................................................
211F.6 FlexLoader assistance and utility functionality ........................................................
218F.7 FlexLoader machine tool interface functionality .......................................................
222F.8 FlexLoader options functionality ..........................................................................
225G FlexLoader Library Add-in reference
225G.1 Instructions ......................................................................................................
225G.1.1 MT_ClearAllPartInfo - Clears all part tracker information .................................
226G.1.2 MT_ClearPartInfo - Resets part information of a part tracker ............................
227G.1.3 MT_CopyPartInfo - Copies part info between trackers ....................................
229G.1.4 MT_CreateAlarm - Creates new alarm or message ........................................
230G.1.5 MT_ErrWrite - Creates error log message in local language ............................
231G.1.6 MT_GetPartInfo - Gets any kind of part tracker data from a part tracker .............
233G.1.7 MT_GoHome - Moves robot to home zone ...................................................
234G.1.8 MT_InitializeMessageHandling - Initiates the alarms and messaging module ......
235G.1.9 MT_Log - Creates a log message in log file ..................................................
236G.1.10 MT_LogEnable - Enables or disables logging ...............................................
237G.1.11 MT_MovePartInfo - Moves part info between part trackers ..............................
239G.1.12 MT_MoveRobotTo - Moves robot to a specific zone .......................................
240G.1.13 MT_MoveToStart - Moves robot to closest start position .................................
241G.1.14 MT_MoveToZoneMenu - Shows manual menu to move between zones .............
242G.1.15 MT_ResetAlarms - Resets all or a specific alarm ...........................................
243G.1.16 MT_SetAlarm - Sets an alarm to active ........................................................
244G.1.17 MT_SetPartInfo - Sets part information of a part in a specific tracker .................
245
G.1.18 MT_UpdateMessageTextsIfNeeded - Reads messages into message array if
needed ..................................................................................................
246G.2 Functions ........................................................................................................
246G.2.1 MT_GetActiveAlarm - Get an active alarm data .............................................
247G.2.2 MT_GetCurrentZone - Get zone where robot is positioned now ........................
248G.2.3 MT_GetMessage - Get complete message data ............................................
249G.2.4 MT_GetNumberOfActiveAlarms - Gets number of active alarms .......................
250G.2.5 MT_GetPartState - Gets current part state of a part in specific tracker ...............
251G.2.6 MT_GetText - Gets a selected text line from a message ..................................
253G.2.7 MT_GetViaPosition - Gets corresponding via position for a zone ......................
254G.2.8 MT_IsAlarmActive - Check if an specific alarm is active ..................................
255G.2.9 MT_UIBoolEntry - Show an yes no question in localized language ....................
259G.2.10 MT_UIDNumEntry - Shows a localized dnum entry ........................................
263G.2.11 MT_UIMessageBox - Show a message box in localized language .....................
267G.2.12 MT_UINumEntry - Shows a num entry box in localized language ......................
271G.3 Data types .......................................................................................................
271G.3.1 mtaxisrange - specifies an axis with an axis range .........................................
272G.3.2 mtloglevel - define a log level ....................................................................
273G.3.3 mtmsgdata - alarm and message definition data ...........................................
275G.3.4 mtpartdata - Describes a part ....................................................................
276G.3.5 mtpartstate - Describes a part state ............................................................
277G.3.6 mtparttracker - describes all data for a part tracker ........................................
279G.3.7 mtrange - describes a robot axis range ........................................................
280G.3.8 mtstationdata - describes a station .............................................................
281G.3.9 mttargetdata - describes a robot zone .........................................................
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Overview of this manual
About this manual
FlexLoader SC 6000 is a standard cell used for machine tool tending. This manual
describes how to install, operate, maintain, service and troubleshoot the FlexLoader
SC 6000.
Usage
This manual should be used during:
• installation and preparation work
• maintenance work
• repair work
• service work
• operation.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel
• service personnel
• operators.
Prerequisites
Operators and maintenance, repair and installation personnel working with an ABB
robot must be trained by ABB and have the required knowledge of mechanical and
electrical installation, service and maintenance work.
Trademarks
FlexLoader is a trademark of ABB.
References
Document IDReference
3HAA009719-001Product specification - FlexLoader SC 6000
3HAC051771-001Product manual - FlexLoader Vision
3HAC033453-001Product manual - IRB 2600
3HAC033453-001Product manual - IRB 4600
3HAC027707-001Product manual - IRC5 Panel Mounted Controller
3HAC051769-001Application manual - FlexLoader Standard Safety Center
Revisions
DescriptionRevision
First edition.A
Continues on next page
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Overview of this manual

DescriptionRevision
General update. Improved RAPID description and reference.B
Clarifications on PROFINET setupC
Updated for R19D.D
Includes new RAPID program setup.
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Overview of this manual
Continued

1 Getting started
Basic steps for integrators
Follow the steps below for getting started with a FlexLoader SC 6000 system.
Action
Become familiar with this manual.1
Transport the FlexLoader SC 6000 to its intended location and integrate it with machine
tool(s) and other equipment.
2
See Installation on page 25.
Pay special attention to safety and functional interface.3
See Interface on page 79.
Prepare the vision system.4
See Vision system FlexLoader Vision on page 59 and Product manual - FlexLoader
Vision.
Calibrate all camera work objects.5
See Product manual - FlexLoader Vision.
Calibrate all robot work objects.6
See Calibration of the coordinate systems on page 61.
Use a simple detail and perform a basic teachin.7
See Product manual - FlexLoader Vision.
Adjust the robot program to fit the needs of the robot cell.8
See RAPID program on page 91.
Perform a first pick with the robot at low speed.9
See Operation on page 119.
Make final teachin and refinements to to robot code.10
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1 Getting started

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2 Safety
2.1 Introduction
This chapter contains safety information for procedures where there is a risk of
personal injury or damage to property.
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. Personnel working with the robot must be familiar
with the operation and handling of the robot, as described in the applicable
documents.
• Only personnel with required training are authorized to use the system.
• All received training must be documented in writing.
System integ-
rator
Qualified elec-
trician
Trained service and
maintenance techni-
cian
Trained operat-
or
Activity
XCommissioning
XXOperation
XXTrouble-shooting
XCorrection of
mechanical fault
XCorrection of elec-
trical fault
XService
XMaintenance
x = Authorized to perform the activity.
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2 Safety
2.1 Introduction

2.2 Safety during installation, commissioning and decommissioning
Always check that the installation and maintenance instructions are supplied
together with the machine. Carefully read the safety information, before unpacking
and installing the equipment.
Personnel who are involved in the installation and commissioning must have
relevant training for the respective robot and corresponding safety issues.
WARNING
Maintain established good work practices with regard to robot safety.
Ensure that nobody is within the safeguarded area during automatic operation.
CAUTION
It is forbidden to enter the conveyor. Ensure that nobody is on the conveyor,
especially when the belt is in motion.
CAUTION
It is forbidden to step on the illumination roof, the outer walls of the FlexLoader
SC 6000 and on any FlexLoader SC 6000 option.
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2 Safety
2.2 Safety during installation, commissioning and decommissioning

2.3 Safety during setup, maintenance, service and repair
Always ensure that FlexLoader SC 6000 cannot be started when working on the
cell. The installed protection that belongs to the equipment must always remain
installed during automatic operation.
Work on mechanical systems must only be carried out by qualified person or by
a trained person under guidance and supervision of a qualified person according
to the applicable technical regulations.
Work on electrical systems or operating material must only be carried out by a
qualified electrician or by a trained person under guidance and supervision of a
qualified electrician according to the applicable electrical technical regulations.
The following must be performed before performing work on FlexLoader SC 6000:
• Emergency stop must be activated (FlexLoader SC 6000 not in operation).
• The voltage supply to the robot cell must be disconnected.
• Action must be taken so that the voltage supply to the robot cell cannot be
connected when work is carried out on the conveyor belt. Use the available
lockout device.
• The air supply must be disconnected. Use the available lockout device.
•The key for resetting the protective stop must be carried when working within
the safeguarded area of FlexLoader SC 6000.
Note that mechanical, pneumatic or electrical energy may be stored in FlexLoader
SC 6000. Take the necessary precautions when carrying out work in the robot cell.
All safety and warning signs must be kept clean and legible. If necessary, replace
them.
Always check the function of all safety devices after performing work that may
have had an impact on the safety systems.
CAUTION
Ear and eye protection shall be used when working with an air cleaning
box/deburring unit. The need will depend on the application and shall be risk
assessed.
CAUTION
Ear and eye protection shall be used when working with an air nozzle on the
gripper system.
CAUTION
Protective shoes shall be used when working with the FlexLoader SC 6000. The
need will depend on the application and shall be risk assessed.
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2 Safety
2.3 Safety during setup, maintenance, service and repair

CAUTION
Pneumatic energy can be stored in the gripper system. Be aware of crushing
risk.
CAUTION
Details held in the gripper can fall down after an extended period of depressurized
state, if the grippers are equipped with pressure retaining valves. Be aware of
crushing risk.
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2 Safety
2.3 Safety during setup, maintenance, service and repair
Continued

2.4 SafeMove
Standard operation
The robot working space in the FlexLoader SC 6000 is restricted by the use of
SafeMove. Due to space requirements, the SafeMove outer boundaries of restricted
space are close to the FlexLoader SC 6000 enclosure.
In case of robot malfunction or erroneous programming leading to a movement
out of the restricted space, the robot will begin to stop its movement. Minor
collisions with the outer FlexLoader SC 6000 housing can occur, but will not lead
to a personal hazard.
The working space is restricted by a set of FlexLoader SC 6000 internal zones,
and an additional set of FlexLoader SC 6000 external SafeMove zones.
DANGER
The internal SafeMove configuration shall not be disabled or modified for any
reason.
DANGER
The external SafeMove configuration towards the machine tool must be adopted
to the actual application.
Risk assessment must be performed, and the new SafeMove configuration must
be validated.
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2 Safety
2.4 SafeMove

Alternate mounting position.
For some FlexLoader products, the mechanical configuration does allow an alternate
mounting position of the robot. This possibility is given for the integrators
convenience and shall not be considered to be a standard option.
If the wall towards the machine tool is (partly) removed, the alternate mounting
position of the robot will move the robot ~100 mm closer to the machine tool.
xx1900000185
DescriptionPos.
Standard mounting positionA
Alternative mounting positionB
The SafeMove configuration must be changed accordingly to the new work space.
The standard ABB guidelines for configuration and validation of SafeMove
configurations shall be followed.
DANGER
It is the integrators responsibility to modify and validate the SafeMove
configuration for the alternate mounting position in a suitable way.
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2 Safety
2.4 SafeMove
Continued

2.5 Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the FlexLoader SC 6000 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.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of FlexLoader SC 6000 in other ways than intended.
• Incorrect operation or maintenance.
• Operation of FlexLoader SC 6000 when the safety devices are defective, not
in their intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
•Non-authorized design modifications made in or around FlexLoader SC 6000.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
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2 Safety
2.5 Limitation of liability

2.6 Nation and region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where FlexLoader SC 6000 is installed.
Within the EU, refer to the Machinery Directive 2006/42/EC with addendum.
In the US, refer e.g. to ANSI/RIA R15.06 (Industrial Robots and Robot Systems -
Safety Requirements) and UL 1740 (Standard for Robots and Robotic Equipment).
In Canada, refer e.g. to CAN/CSA-Z434-03 (Industrial Robots and Robot Systems
- General Safety Requirements).
Note
The supplied equipment must not be operated until the processing machine or
system in which the equipment is included, has been approved according to
national and regional laws and regulations.
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2 Safety
2.6 Nation and region specific regulations