ABB SafeMove2 Instructions for use

ROBOTICS
Application manual
Functional safety and SafeMove2

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Application manual
Functional safety and SafeMove2
RobotWare 6.11.02
Document ID: 3HAC052610-001
Revision: P
© Copyright 2016-2020 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, damage 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 2016-2020 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
13Product documentation ....................................................................................................................
15Safety ................................................................................................................................................
171 Introduction
171.1 Overview of functional safety ...............................................................................
201.2 Safety .............................................................................................................
201.2.1 Safety aspects for the safety module and SafeMove ......................................
211.2.2 Standards conformance ...........................................................................
221.2.3 Specific safety requirements .....................................................................
231.2.4 Safe design of SafeMove ..........................................................................
251.2.5 Certifications ..........................................................................................
261.2.6 Conclusion .............................................................................................
271.3 Limitations .......................................................................................................
321.4 Terminology .....................................................................................................
331.5 Abbreviations and acronyms ...............................................................................
352 SafeMove functions
352.1 Overview of SafeMove functions ..........................................................................
382.2 General functions ..............................................................................................
382.2.1 Manual Operation Supervision ...................................................................
392.2.2 Contact Application Tolerance (CAP) ..........................................................
412.3 Synchronization functions ...................................................................................
412.3.1 Software synchronization ..........................................................................
422.3.2 Hardware synchronization ........................................................................
442.4 Supporting functions ..........................................................................................
442.4.1 Safe Brake Ramp ....................................................................................
462.5 Supervision functions ........................................................................................
462.5.1 Stand Still Supervision (SST) .....................................................................
482.5.2 Axis Speed Supervision (ASP) ...................................................................
492.5.3 Tool Speed Supervision (TSP) ...................................................................
512.5.4 Axis Position Supervision (APO) ................................................................
532.5.5 Tool Position Supervision (TPO) ................................................................
542.5.6 Tool Orientation Supervision (TOR) ............................................................
552.5.7 Control Error Supervision .........................................................................
573 Installation
573.1 Hardware .........................................................................................................
573.1.1 Safety module ........................................................................................
583.1.2 Sync switch ............................................................................................
593.2 Software ..........................................................................................................
603.3 Safe fieldbuses .................................................................................................
603.3.1 About safe fieldbuses ..............................................................................
623.3.2 The I/O Engineering Tool ..........................................................................
633.3.3 CIP Safety Adapter ..................................................................................
653.3.4 PROFIsafe F-Device ................................................................................
663.3.5 PROFIsafe F-Host ...................................................................................
673.3.6 ABB CI502 PROFINET I/O device ...............................................................
683.4 Remote control of operating mode ........................................................................
683.4.1 Overview ...............................................................................................
693.4.2 Timing and error handling .........................................................................
713.5 System inputs and outputs ..................................................................................
734 The Visual SafeMove user interface in RobotStudio
734.1 About Visual SafeMove ......................................................................................
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744.2 The user interface .............................................................................................
764.3 The Visual SafeMove tab ...................................................................................
764.3.1 About the Visual SafeMove tab .................................................................
794.3.2 Adding SafeMove functions .......................................................................
844.4 The Modify tab .................................................................................................
874.5 The Visual SafeMove browser .............................................................................
914.6 The Safe IO Configurator ...................................................................................
914.6.1 Introduction ............................................................................................
924.6.2 Signals view ...........................................................................................
974.6.3 Function mappings ..................................................................................
994.6.4 Pre-logic and post-logic ............................................................................
1024.6.4.1 Description of the complex operators ..............................................
1084.6.5 Safe I/O system rules and limitations ..........................................................
1094.7 Simulating SafeMove .........................................................................................
1104.8 Protected basic configuration ..............................................................................
1135 The FlexPendant user interface
1135.1 The Safety Controller control panel ......................................................................
1185.2 The Keyless Mode Selector .................................................................................
1215.3 Safemove Visualizer ..........................................................................................
1215.3.1 Introduction ............................................................................................
1235.3.2 The Safe Zone Config tab .........................................................................
1235.3.2.1 Introduction ................................................................................
1255.3.2.2 Navigating the graphical view ........................................................
1275.3.2.3 Depth change in the side view of the graphical display .......................
1295.3.2.4 Zone data in the Safe Zone Config tab ............................................
1305.3.3 The Last Zone Violation tab ......................................................................
1335.3.3.1 Zone data in the Last Zone Violation tab .........................................
1355.3.4 The Safe Ranges tab ...............................................................................
1376 Configuring SafeMove
1376.1 Recommended working procedure .......................................................................
1396.2 Preparations ....................................................................................................
1406.3 Configure system parameters ..............................................................................
1416.4 Set up safety user grants ....................................................................................
1436.5 Starting Visual SafeMove ....................................................................................
1446.6 Configure Manual Operation Supervision ...............................................................
1456.7 Configure the robot ............................................................................................
1476.8 Configure additional axes ...................................................................................
1486.9 Configure the synchronization position ..................................................................
1496.10 Configure the tools ............................................................................................
1526.11 Configure safe I/O .............................................................................................
1556.12 Configure the zones ...........................................................................................
1576.13 Configure the ranges .........................................................................................
1596.14 Global supervision functions ...............................................................................
1606.15 Configure the supervision functions ......................................................................
1686.16 Configure other functions ...................................................................................
1706.17 Save the configuration .......................................................................................
1716.18 Load the configuration to the safety controller ........................................................
1716.18.1 Loading a safety configuration using RobotStudio .........................................
1726.19 Configuration for MultiMove ................................................................................
1736.20 Validate the configuration ...................................................................................
1866.21 Restore configuration .........................................................................................
1876.22 Reset safety controller to factory settings ..............................................................
1886.23 Upgrading and installing new systems ..................................................................
1897 Running in production
1897.1 Reaction time ...................................................................................................
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1907.2 Restarting the controller .....................................................................................
1917.3 Recovery after safety violation .............................................................................
1927.4 Changes to robot or robot cell .............................................................................
1938 Maintenance
1938.1 Required maintenance activities ..........................................................................
1959 RAPID components
19710 Reference information
19710.1 Synchronization guidelines .................................................................................
19710.1.1 Software synchronization guidelines ...........................................................
19910.1.2 Hardware synchronization guidelines ..........................................................
20010.2 Cyclic Brake Check guidelines .............................................................................
20410.2.1 Cyclic Brake Check signal description .........................................................
20810.3 Servo Delay Factor and Servo Lag .......................................................................
21010.4 Connection of external emergency stop .................................................................
21210.5 SafeMove geometry configuration file ...................................................................
21210.5.1 Introduction ............................................................................................
21410.5.2 Use cases ..............................................................................................
21610.5.3 Explanation of the configuration file ............................................................
21610.5.3.1 Introduction ................................................................................
21810.5.3.2 Drive module configuration ............................................................
21910.5.3.3 Robot data .................................................................................
22110.5.3.4 External axis ...............................................................................
22210.5.3.5 Tool ..........................................................................................
22510.5.3.6 Safe zones .................................................................................
22710.5.4 Example ................................................................................................
23010.6 How to establish CIP Safety communication with a PLC ...........................................
23010.6.1 Introduction ............................................................................................
23210.6.2 Configuring the ABB CIP Safety Adapter in Studio 5000® ...............................
235Index
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Overview of this manual
About this manual
This manual describes the safety module, the functional safety options, and the
second generation of SafeMove. It contains descriptions of the functionality, and
how to configure that functionality. It also describes user interfaces and
recommendations on how to use the safety module.
Usage
This manual should be used during installation and configuration of the safety
module, SafeMove, and the functional safety options.
Who should read this manual?
This manual is mainly intended for:
• personnel that are responsible for installations and configurations of
hardware/software
• personnel that make configurations of the I/O system
• system integrators
Prerequisites
The reader should have the required knowledge of:
• mechanical installation work
• electrical installation work
• working with industrial robots
• using RobotStudio
• personal safety, see Safety manual for robot - Manipulator and IRC5 or
OmniCore controller.
References
Document IDReference
3HAC051016-001Application manual - Additional axes and stand alone controller
3HNA026812Application manual - Functional safety and SafeMove for paint
3HAC065546-001Application manual - PROFINET Controller/Device
For RobotWare 6.08.01 and later.
3HAC050998-001Application manual - EtherNet/IP Scanner/Adapter
3HAC032104-001Operating manual - RobotStudio
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller
3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio
3HAC047136-001Product manual - IRC5
IRC5 of design 14
3HAC050917-001Technical reference manual - RAPID Instructions, Functions and
Data types
Continues on next page
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Overview of this manual

Document IDReference
3HAC048645-001Product specification - Robot stopping distances according to
ISO 10218-1
3HAC050948-001Technical reference manual - System parameters
3ADR024128K0201Application Note - Unbundled S500 Safety I/Os
Revisions
DescriptionRevision
Released with RobotWare 6.03.-
Released with RobotWare 6.03.01.
• Minor corrections.
• Added section Connection of external emergency stop on page 210.
• There can now be two Tool Position Supervision functions per zone.
• IRB 1660ID added to list of supported robots.
• Added section Additional grants that may be required when working
with SafeMove on page 142.
A
Released with RobotWare 6.04.
• The External Power Supply button is renamed to General Output, see
The General Output button on page 83.
• Minor corrections.
B
Released with RobotWare 6.04.01.
• Updated section Safe fieldbus parameters on page 92.
• Updated section The Keyless Mode Selector on page 118.
• Added section Reset safety controller to factory settings on page 187.
• Updated section Cyclic Brake Check guidelines on page 200.
• Added section Connection of external emergency stop on page 210.
• Minor corrections.
C
Released with RobotWare 6.05.
• Updated section Robots supported by SafeMove on page 27.
• Added limitations for MultiMove and SoftMove, see Limitations on
page 27.
• Added section Remote control of operating mode on page 68.
• Updated section Restore configuration on page 186.
• Added section Upgrading and installing new systems on page 188.
• Minor corrections.
D
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Continued

DescriptionRevision
Released with RobotWare 6.05.01.
•Clarifications to better distinguish between the safety module hardware
and software options, for example SafeMove, throughout the manual.
• Added section Exclude from configuration on page 36 and updated
section Robot parameters node on page 87.
• Added the safe fieldbuses PROFIsafe F-Host and F-Device and CIP
Safety Adapter in section Safe fieldbuses on page 60,
• Added section The I/O Engineering Tool on page 62.
• Updated section Remote control of operating mode on page 68.
• Updated sections The Safe IO Configurator on page 91 and Configure
safe I/O on page 152.
• Added new logical operators in section Configuring combinatory logic
on page 99.
• Added information about system parameter Use checkpoint limitation
in world in section Configure system parameters on page 140.
• Updated section Cyclic Brake Check guidelines on page 200.
• Added section SafeMove geometry configuration file on page 212.
• Added section How to establish CIP Safety communication with a PLC
on page 230.
• Minor corrections.
E
Released with RobotWare 6.06.
• SafeMove now supports MultiMove systems with four robots, see
MultiMove on page 31.
• Minor corrections.
F
Released with RobotWare 6.07.
•Changed manual name to indicate that it covers the function SafeMove2
and not SafeMove1.
•SafeMove now supports Stand alone controller, with some restrictions.
See Limitations on page 27.
• Updated picture of FlexPendant user interface in section The Safety
Controller control panel on page 113.
• IRB 6700Inv added to supported robots.
• Some functionality regarding PROFIsafe is moved to I/O Configurator.
Information moved to Application manual - PROFINET Control-
ler/Device.
• Added the system input ProfiSafeOpAck.
G
Released with RobotWare 6.08.
• Removed section Loading a safety configuration using FlexPendant,
since only RobotStudio should be used for loading a configuration.
• Added information and code example to section Cyclic Brake Check
for MultiMove systems on page 201.
• Added IRB 6790 to list of supported robots.
• Changes in section Description of safety functions on page 97: Re-
moved ExternalPowerControlFeedback. Added table footnotes of re-
quired options for some of the functions.
• Clarified descriptions in Configuration group on page 76.
• Changes to Safe fieldbus parameters on page 92. Added references
to other manuals.
• Minor updates of user interface, described in The Visual SafeMove tab
on page 76.
H
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Continued

DescriptionRevision
Released with RobotWare 6.09.
• New graphics added in section Description of the complex operators
on page 102.
• Clarification in section Connection of external emergency stop on
page 210.
• Added information about the floor plan, see Validate the configuration
on page 173.
• Added limitations for gantry and for IRB 1200 Type A.
• The tool I/O Configurator is renamed to I/O Engineering Tool.
J
Released with RobotWare 6.10.
•Clarified information about Logix Designer, see Introduction on page 230.
K
Released with RobotWare 6.10.01.
• Limitations for MultiMove systems added in section MultiMove on
page 31.
L
Released with RobotWare 6.10.02.
• Clarified information about maintenance, see Verify that the contacts
on the panel board are connected as intended on page 184, and Required
maintenance activities on page 193.
• Added limitation for Electronically linked motors, see Electronically
linked motors on page 30.
M
Released with RobotWare 6.11.
•Stand Still Supervision is now possible in manual mode, see Configuring
Stand Still Supervision on page 166.
• The service mode is updated, see The Mode tab on page 115.
• Changes regarding Basic joint supervision made in section Limitations
on page 27,Overview of SafeMove functions on page 35,Manual Op-
eration Supervision on page 38,Safe Brake Ramp on page 44 and The
Visual SafeMove browser on page 87.
N
Released with RobotWare 6.11.02.
• Updates for VSM.
• Added note about upgrading RobotWare, see Upgrading and installing
new systems on page 188.
• Minor corrections.
• Updated screenshots in Configuring SafeMove on page 137.
• Added a new section for Feedback coupling in Pre-logic and post-logic
on page 99.
P
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Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

Safety
Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety information in the product manuals for the robot.
The integrator of the robot system is responsible for the safety of the robot system.
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Safety

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1 Introduction
1.1 Overview of functional safety
Purpose
The purpose of the safety module and the functional safety options is to provide
a robust and easy-to-use safety controller in the robot system. Functional safety
includes a complete software and hardware solution that is fully integrated with
the robot controller and the RobotStudio programming environment.
SafeMove is the main functional safety option, but the safety module can also be
used in various applications without the SafeMove option. For example to
communicate with a safety PLC through safe fieldbus communication, or when
using the keyless mode selector.
SafeMove functions
When using SafeMove, the safety controller ensures a high safety level in the robot
system by using supervision functions that can stop the robot. Note that the safety
module and the functional safety options is one component in the safety system
of a complete robot cell, normally complemented by other equipment (for example
light barriers) for detecting the whereabouts of the operator.
DescriptionFunction
Protects the operator and enhances machine and equipment safety
by supervising the position (Tool Position Supervision), speed (Tool
Speed Supervision) and orientation (Tool Orientation Supervision)
of the tool.
Tool supervision
functions
Protects the surroundings by supervising the axis position (Axis
Position Supervision) and the axis speed (Axis Speed Supervision).
Axis supervision
functions
Supervises the stand-still of robot axes without having to switch the
robot to Motors Off. It enables operators to perform tasks in the
immediate vicinity of the robot.
Stand Still Supervi-
sion
Allows the robot to be in contact with the work-piece in limited areas.
This can for example be used in applications where the robot is
used for grinding or during tool change.
Contact application
tolerance
Supervises that the brakes are checked with a cyclic interval.Cyclic brake check
Triggers stop of the robot using safe fieldbus inputs from the safety
PLC.
Stop functions
Some examples of applications:
• Manual loading stations
• Manual workpiece inspection during operation
• Optimization of cell size
• Protection of sensitive equipment
• Ensuring safe orientation of emitting processes
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1 Introduction
1.1 Overview of functional safety

Functional safety options
To use SafeMove or any of the functional safety options it is necessary to have
the safety module in the IRC5 controller:
• [996-1] Safety module (DSQC1015)
The following options can be ordered together with the safety module:
• [997-1] PROFIsafe F-Device
• [997-2] PROFIsafe F-Host&Device
• [997-3] CIP Safety Adapter
• [997-4] CIP Safety Scanner And Adapter
• [1241-1] Prepared for ABB CI502
• [1125-1] SafeMove Basic
• [1125-2] SafeMove Pro
• [735-7] Keyless Mode Selector, 3 modes
• [735-8] Keyless Mode Selector, 2 modes
• [731-1] Safety Internal conn.
• [731-2] Safety external conn.
Visual SafeMove
The safety module option gives you access to the Visual SafeMove configurator
in RobotStudio. With Visual SafeMove you can:
• configure and visualize supervision functions in a 3D environment.
• configure stop functions, such as automatic stop.
• configure Cyclic Brake Check.
• configure safe signals (safe Ethernet communication and I/Os)
• configure signal logics.
• configure system status outputs.
SafeMove Basic and SafeMove Pro
The below table lists the differences between SafeMove Basic and SafeMove Pro.
SafeMove BasicSafeMove ProFunction
99Supported number of axes
88Safe ranges
116Safe zones
-16 toolsTool changer support
YesYesAxis Position Supervision
-YesAxis Speed Supervision
88Total Global Supervision
-YesTool Orientation Supervision
1YesTool Position Supervision
-YesTool Speed Supervision
-YesStand Still Supervision
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1 Introduction
1.1 Overview of functional safety
Continued

SafeMove BasicSafeMove ProFunction
YesYesContact application support
Basic approach
This is the general approach for setting up the safety module and SafeMove.
1Connect the safety controller to other safety hardware and configure the safe
I/O connections.
2 Configure the settings for the SafeMove functions via Visual SafeMove.
3Download the configuration to the the safety controller. Restart the controller.
4 Synchronize the safety controller.
5 Make sure the activation input signals are activating the desired supervision
functions.
6 Validate the configuration.
7 Lock the configuration.
For more detailed instructions, see sections Installation on page 57 and Configuring
SafeMove on page 137.
Requirements
Robust supervision functionality in SafeMove requires correct settings of payload
and additional axes, since this will affect the calculated accepted servo lag. Please
also note that external forces applied on the manipulator can cause a negative
influence on the supervision functions, since the servo lag might differ from the
calculated values, due to such external forces.
DANGER
A SafeMove configuration must always be validated to verify that the desired
safety is achieved. If no validation is performed, or the validation is inadequate,
the configuration cannot be relied on for personal safety.
The validation must also consider that the braking starts after a zone is violated,
so additional stopping distances may be required, which depend on many factors,
for example mass and speed.
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1 Introduction
1.1 Overview of functional safety
Continued

1.2 Safety
1.2.1 Safety aspects for the safety module and SafeMove
Overview
The safety module is an integrated safety controller in the robot controller, with
the purpose of providing safety functionality for the robot. Safe output and input
signals are typically connected to cell safety circuitry by safe communication with
a safety PLC. The safety PLC can take care of interlocking in the robot cell, for
example, in order to prevent robot and operator to enter a the same area at the
same time.
In this chapter we describe how the safety module and SafeMove comply with
relevant safety standards and regulations.
Note
The safety module and SafeMove is only a part of the robot system, it is the
responsibility of the user to do a risk assessment of the robot system. It is also
the responsibility of the user of SafeMove to ensure that the robot system is
designed and installed in accordance with the safety requirements set forth in
the standards and regulations of the country where the robot system is installed.
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1 Introduction
1.2.1 Safety aspects for the safety module and SafeMove