ABB FlexLoader Instructions for use

ROBOTICS
Application manual
FlexLoader Standard Safety Center

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

Application manual
FlexLoader Standard Safety Center
R19D
Document ID: 3HAC051769-001
Revision: E
© 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
7Overview of this manual ...................................................................................................................
91 Safety
91.1 Introduction ......................................................................................................
101.2 Safety during installation, commissioning and decommissioning ................................
111.3 Safety during setup, maintenance, service and repair ..............................................
121.4 Limitation of liability ...........................................................................................
131.5 Nation and region specific regulations ...................................................................
141.6 To be observed by the supplier of the complete system ............................................
161.7 Safety signals in the manual ................................................................................
192 Description of the product
213 Installation
294 Maintenance
315 Interface
315.1 External safety interface to connected system ........................................................
385.2 Internal safety interface ......................................................................................
436 Function description
457 Operation
457.1 Starting from a non-powered status ......................................................................
467.2 Protective stop .................................................................................................
498 Decommissioning
498.1 General ...........................................................................................................
508.2 Environmental information ..................................................................................
53A Technical data
53A.1 Introduction ......................................................................................................
54A.2 Safety functions ................................................................................................
57A.3 Error messages ................................................................................................
58A.4 Starting from a non-powered status ......................................................................
59A.5 Pluto I/O ..........................................................................................................
61A.6 Safety center response times ..............................................................................
62A.7 Installation guide ...............................................................................................
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Table of contents

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Overview of this manual
About this manual
FlexLoader Standard Safety Center is a safety solution used for the FlexLoader
product family. This manual describes how to install, operate, maintain, service
and troubleshoot the FlexLoader Standard Safety Center.
Usage
This manual should be used during:
• installation and preparation work
• maintenance work
• repair work
• service work
• operation.
This manual is focused on countries where relevant ISO safety standards and
safety regulations according to Machinery Directive 2006/42/EC with addendum
apply.
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
• The product manual of the robot used together with FlexLoader Standard
Safety Center.
• The product manual of the FlexLoader function package or standard cell
used with FlexLoader Standard Safety Center.
• The product manual of the machine tool/s used together with the FlexLoader
function package or standard cell.
• The Pluto product manuals.
Continues on next page
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Overview of this manual

• Suggestion of applicable standards
- EN ISO 13849-1 “Safety of machinery -- Safety related parts of control
systems. General principles for design”
- EN ISO 12100 “Safety of machinery – General principles for design –
Risk assessment and risk reduction”
- EN 62061 “Safety of machinery – Functional safety of safety-related
electric, electronic and programmable electronic control systems”
- EN ISO 14119 “Safety of machinery – Interlocking devices associated
with guards – Principles for design and selection”
- EN 60204-1 “Safety of machinery. Electrical equipment of machines.
General requirements.”
- Newer applicable standards and regulations supersede the above
standards.
Revisions
DescriptionRevision
First edition.A
Updated illustrations.B
General update.C
Include Profinet update. Improved information on master/slave interfaces.D
Minor updates.E
Added section on response times.
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Overview of this manual
Continued

1 Safety
1.1 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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1 Safety
1.1 Introduction

1.2 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.
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1 Safety
1.2 Safety during installation, commissioning and decommissioning

1.3 Safety during setup, maintenance, service and repair
Always ensure that FlexLoader Standard Safety Center 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.
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.
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1 Safety
1.3 Safety during setup, maintenance, service and repair

1.4 Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the FlexLoader Standard Safety Center 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 Standard Safety Center in other ways than intended.
• Incorrect operation or maintenance.
• Operation of FlexLoader Standard Safety Center 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 Standard
Safety Center.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
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1 Safety
1.4 Limitation of liability

1.5 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 Standard Safety Center 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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1 Safety
1.5 Nation and region specific regulations

1.6 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 FlexLoader Standard Safety Center are designed and
installed correctly.
When integrating FlexLoader Standard Safety Center with external devices and
machines:
• The supplier of the complete system must ensure that all circuits used in the
protective stop function are interlocked in a safe manner, in accordance with
the applicable standards for the protective stop function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
• The supplier of the complete system must ensure that all circuits used in all
other safety function are interlocked in accordance with the applicable
standards for that function.
The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The robot system shall be designed to allow safe access to all areas where
intervention is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the robot’s working space. Light beams or sensitive mats are suitable devices.
Turn-tables or the like should be used to keep the operator out of the robot’s
working space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the manipulator to protect those working with or on it
from hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the robot is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the robot axes and
from the position at which the robot is working in the work cell (see the Robot
product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot or positioned stationary in the cell.
Continues on next page
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1 Safety
1.6 To be observed by the supplier of the complete system

The FlexLoader Standard Safety Center used with Eden door switches does not
evaluate door locking in its safety function. This has to be considered in the risk
assessment.
Safe handling
Make sure that the users cannot be exposed to hazards, including slipping, tripping,
and falling hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that the guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation.
Safe design
The emergency stop buttons must be positioned in easily accessible places so
that the system can be stopped quickly. If any of the buttons do not stop all the
robot workcell motion, each emergency stop button must be marked (if more than
one is provided) to indicate its designated safety function.
Changes to Pluto program
Applicable for systems with the optional safety center.
WARNING
The Pluto program is a critical part of the automation cell's safety system.
Apart from configuration changes, no other changes may be made without
qualified review and validation regarding safety risks, safety functions and the
overall behavior of the safety system.
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1 Safety
1.6 To be observed by the supplier of the complete system
Continued

1.7 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
SignificanceDesignationSymbol
Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
DANGER
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in serious
injury.
WARNING
Signal word used to indicate a potentially hazardous
situation related to electrical hazards which, if not
avoided, could result in serious injury.
ELECTRICAL
SHOCK
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in slight
injury.
CAUTION
Signal word used to indicate a potentially hazardous
situation which, if not avoided, could result in severe
damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
Signal word used to indicate important facts and
conditions.
NOTE
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1 Safety
1.7 Safety signals in the manual

SignificanceDesignationSymbol
Signal word used to indicate where to find additional
information or how to do an operation in an easier
way.
TIP
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1 Safety
1.7 Safety signals in the manual
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2 Description of the product
General
WARNING
Applicable training is required in order to use the product. Incorrect use of the
product can lead to personal injury and material damage. Before commissioning
the product, it is your responsibility to carefully read the chapter Safety on
page 9, and to be familiar with the safety devices.
FlexLoader Standard Safety adds safety features needed for a complete robot cell.
It is based on the ABB Pluto programmable safety controller.
It handles emergency stops and protective stops in the cell and ensures safe and
reliable interaction with external equipment.
FlexLoader Standard Safety can be configured and covers a broad range of safety
interface needs.
DANGER
The Pluto program is a critical part of the safety system of the cell. No changes
may be carried out without a qualified inspection and verification of the safety
risks and the behavior of the safety system as a whole.
Area of use
FlexLoader Standard Safety must only be used in cells with intended safety
classification and on the condition that the applicable safety requirements and
standards are followed.
Performance level
The safety functions for ABB’s components (emergency stop and protective stop)
according to this description fulfil the performance level PLd in accordance with
EN ISO 13849:1.
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2 Description of the product

Typical integration example
The equipment can be integrated in several different ways. Below is a typical
example of how the safety center can be integrated with other equipment. The
example shows the FlexLoader Standard Safety Center with all connected devices.
xx1800002552
Pos.DescriptionPos.
Service PCGInternal door safety chain (single
chain)
A
Internal emergency stop chainB
Dynamic safety signalDynRobot controller with robot(s)C
Emergency stop, two-channel, poten-
tial free
ESFlexLoader function packageD
Protective stop, two-channel, poten-
tial free
PSEquipment with elevated risk level,
e.g. deburring, cutting, air cleaning.
E
Connected systemKFlexLoader Standard SafetyF
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2 Description of the product
Continued