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 .......................................................
Product manual - FlexLoader SC 6000 5
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© Copyright 2014-2020 ABB. All rights reserved.
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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
6 Product manual - FlexLoader SC 6000
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© Copyright 2014-2020 ABB. All rights reserved.
Table of contents

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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© Copyright 2014-2020 ABB. All rights reserved.
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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
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Product manual - FlexLoader SC 6000 9
3HAC051768-001 Revision: D
© Copyright 2014-2020 ABB. All rights reserved.
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.
10 Product manual - FlexLoader SC 6000
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Overview of this manual
Continued