3hac045800 en

ABB Robotics
Product manual
Machine directive safety kit S4C, S4C+, S4C+ Automotive
Trace back information:

Workspace Main version a21 (not checked in)
Published 2012-12-10 at 08:47:00
Skribenta version 1184
Product manual
Machine directive safety kit S4C, S4C+, S4C+ Automotive
Document ID: 3HAC045800-001
Revision: -
Copyright 2012-2012 ABB. All rights reserved.
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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB AB
Robotics Products
SE-721 68 Vsters
Sweden
Table of contents
Table of contents
Overview of this instruction ..............................................................................................................
Safety ................................................................................................................................................
7
8
About the safety kit
Required parts
11
Replacing parts on the teach pendant
13
Replacing parts on the controller
17
Approving and reporting the replacements
25
Index
27
3HAC045800-001 Revision: -
5
This page is intentionally left blank
Overview of this instruction
Overview of this instruction

Prerequisites
A maintenance/repair/installation craftsman working with an ABB manipulator
must:
be trained by ABB and have the required knowledge of mechanical and

electrical installation/repair/maintenance work.
References
Reference
Document Id
Instruction - Brake testing for manipulators
3HAC045784-001
Operating manual - Emergency safety information
3HAC027098-001
Same document number regardless of language.
Operating manual - General safety information for S4C and S4Cplus 3HAC044215-001
i
This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Revisions
Revision
Description
First edition
7
Safety
Safety
Voltage related risks
A danger of high voltage is associated with, for example, the following parts:
Be aware of stored electrical energy (DC link) in the controller.
Units such as I/O modules, can be supplied with power from an external
source.
The mains supply/mains switch
The power unit
The control power supply (S4C 55 VAC, and S4Cplus 230 VAC)
The rectifier unit (262/430 VAC and 400/800 VDC. Note: Capacitors!)
The drive unit (400/800 VDC)
The service outlets (115/230 VAC)
The power supply unit for additional tools, or special power supply units for
the machining process.
The external voltage connected to the control cabinet remains live even when
the robot is disconnected from the mains.
Additional connections.
Safety regulations
Before beginning mechanical and/or electrical installations, make sure you are
familiar with the safety regulations described in the manual Operating
manual - General safety information for S4C and S4Cplus.
3HAC045800-001 Revision: Copyright 2012-2012 ABB. All rights reserved.
1 About the safety kit
1 About the safety kit

The machine directive safety kits
The machine directive safety kits contain necessary spare parts to upgrade the
S4C, S4C+, and S4C+Automotive controllers to meet the machine directive. This
manual describes the kits for all three controllers.
Approval and reporting
All of the replacement procedures that are described in this manual must be
followed by a brake test. After a successful brake test, the replacements must be
approved according to a separate report and then uploaded in WebConfig. See
Approving and reporting the replacements on page 25.
All of the parts in the kit should be replaced at the same time, by the same person,
so that one person can sign the approval.
The brake test is described in a separate document. If the brakes are not working
then the customer must be informed.
Note
The replacement procedure can only be approved if the brake test is successful.
9
2 Required parts
2 Required parts
Required parts
The spare part kits include all the parts that are necessary to replace to fulfill the
machine directive.
There are two kits for each controller model, one with and one without the panel
board. The panel board may need replacing, depending on the revision of the
board.
Note
For S4C: If the revision of the panel board (DSQC 331) is in the range of 1 to 7,
then it should be replaced. If the revision is 8 or higher then there is no need to
change the panel board.
For S4C+ and S4C+Automotive: If the revision of the panel board (DSQC 509)
is in the range of 1 to 4, then it should be replaced. If the revision is 5 or higher
then there is no need to change the panel board.
Tip
The revision of the panel board is printed on the bar code label on the panel
board. The revision number is written as a slash followed by the revision in two
character-format, for example /01 or /06. This number is preceded by the DSQC
number and the article number.
Kits for S4C
Safety kit
Article number
Safety kit with the panel board included
3HAC044339-001
Safety kit without the panel board included
3HAC045620-001
Safety kit
Article number
3HAC044339-002
3HAC045620-002
Kits for S4C+
Kits for S4C+ Automotive

Safety kit
Article number
3HAC044339-003
3HAC045620-003
11
3 Replacing parts on the teach pendant

Replacing the emergency stop
Use this procedure to replace the emergency stop on the teach pendant.
Action
Note
Turn off the power to the controller. If possible, turn off the power to the entire cell
or line.
Disconnect the teach pendant and place it

with the back facing up. If possible, use an
ESD protected area.
Loosen the screws holding the bottom

case. Lift off the bottom case. Be careful
so that the screws do not get lost.
WARNING
Do no touch any components inside the
teach pendant!
Release the contact blocks by pulling the

locking device upwards.
Loosen the nut inside the teach pendant

and then remove the old holder with contact blocks and the emergency stop button.
xx1200001022
Gently place the new emergency stop button in place and put back the nut holding
the emergency stop button.
xx1200001023
Move the wires from the old contact block The terminal numbering is the same, that
to the new button.
is, 11, 12, 21, and 22.
Yellow/white = 11
Yellow/brown = 12
White = 21
Green/brown = 22
Tighten the nut holding the emergency stop

button.
Continues on next page

13

Continued
Action
9
Note
Continue with replacing the enabling

switch, see Replacing the enabling switch
on page 14.
Replacing the enabling switch

Use this procedure to replace the emergency stop on the teach pendant.
Action
1
Note
Disconnect the enabling switch cable from

the board.
xx1200001024
Loosen the nut and remove the plastic

bracket securing the enabling switch buttons.
Remove the cap and release the nut.
Remove the enabling switch and the

cables.
xx1200001025
Put the new enabling switch harness in

place. Secure the cables with tape.
xx1200001026

14

Continued
Action
6
Put the plastic bracket back in place and

tighten the nut fully.
Put the bottom case back in place. Make

sure that no cables stick out or get
squeezed.
Tighten the screws fully.
Continue with replacing the parts on the

controller, see Replacing parts on the controller on page 17.
Note
15
4 Replacing parts on the controller

Replacing parts inside S4C and S4C+
Use this procedure to replace the parts on the S4C and the S4C+ controllers.
Action
1
or line.
Open the top cover of the controller and

the two lids covering the brake and motor
on contactors.
Remove the auto/manual switch to enable

access to the auxiliary contact blocks and
the contactors.
Lift the red lever on the auto/manual switch
up and then pull the switch into the controller. Then take out the auxiliary contact
blocks and the contactors from the controller, with the cables still connected.
Note
xx1200001027
For each brake and motor on contactor:

1 Disconnect the cables from the
auxiliary contact blocks on the contactor. Press the white securing
button and pull each auxiliary contact block from the holder on the
contactor.
2 Reconnect all the cables to the new
auxiliary contact block.
3 Disconnect all the cables from the
contactor.
4 To loosen the contactor from the DIN
rail insert a screwdriver in the slot
and push in designated direction.
Pull it loose.
5 Mount the new contactor on the DIN
rail. Reconnect all the cables to the
new contactor.
6 Mount the new auxiliary contact
block to the holder on the contactor.
Fasten the screws fully.
xx1200001028
xx1200001029

17

Continued
Action
5
Note
Remove the contact blocks for the motor

on button and the emergency stop button.
For S4C also remove the contact blocks
for the main switch.
xx1200001030
Remove the motor on button and the

emergency stop button.
For S4C also remove the main switch.
For S4C: Remove the old front panel and

put the new front panel in place.
Disconnect the harness connector A81.XP6

from the panel board.
If the connector S1.1 X1 (part of the harness) is connected, then disconnect it too.
xx1200001031
Remove the old harness.
10 Install the new harness.

11 Refit the new motor on button and the
emergency stop button, and their new
contact blocks.
For S4C also refit the auto/manual switch
and its contact blocks.
xx1200001032

18

Continued
Action
Note
12 Secure the lids.
xx1200001033
13 If needed, continue with replacing the

panel board, see Replacing the panel board
on page 23.
Otherwise close the controller, reconnect
the power supply cables, and continue with
approving the replacements, see Approving
and reporting the replacements on page 25.
Replacing parts inside S4C+ Automotive

Use this procedure to replace the parts on the S4C+ Automotive controller.
Action
1
or line.
Open the controller door and unplug all the

cables from the base connection unit
(DSQC 504). Loosen and remove the screw
securing the unit and then remove the base
connection unit.
Note
xx1200001034

19

Continued
Action
3
Note
Loosen the screw holding the contactor

board and pull the contactor board out of
the controller.
xx1200001035

20

Continued
Action
4
For each brake and motor on contactor:

1 Disconnect the cables from the
auxiliary contact blocks on the contactor. Press the white securing
button and pull each auxiliary contact block from the holder on the
contactor.
2 Reconnect all the cables to the new
auxiliary contact block.
3 Disconnect all the cables from the
contactor.
4 To loosen the contactor from the DIN
rail insert a screwdriver in the slot
and push in designated direction.
Pull it loose.
5 Mount the new contactor on the DIN
rail. Reconnect all the cables to the
new contactor.
6 Mount the new auxiliary contact
block to the holder on the contactor.
Fasten the screws fully.
Note
xx1200001028
xx1200001029
xx1200001036

21

Continued
Action
5
Note
Remove the contact blocks for the main

switch, the motor on button, and the emergency stop button.
xx1200001037
Remove the main switch, the motor on

button, and the emergency stop button.
Disconnect the harness connector A81.XP6

from the panel board.
If the connector S1.1 X1 (part of the harness) is connected, then disconnect it too.
Disconnect the harness cable from the
panel board.
xx1200001038
xx1200001039
Remove the old harness.
Install the new harness.

22

Continued
Action
Note
10 Refit the new motor on button, the emergency stop button, and the auto/manual
switch, and their new contact blocks.
xx1200001032
11 Connect the connector A81.XP6 to the

panel board. If the connector S1.1 X1 (part
of harness) was connected, then connect
it too.
12 If needed, continue with replacing the
panel board, see Replacing the panel board
on page 23.
Otherwise close the controller, reconnect
the power supply cables, and continue with
approving the replacements, see Approving
Replacing the panel board

Use this procedure to replace the panel board, if needed.
Action
1
Disconnect all cable connectors from the

panel board. Loosen the securing screw.
Remove the old panel board.
Insert the new panel board into the grooves

in the bracket.
Tighten the securing screw and reconnect

all the cable connectors to the panel board.
Connect the power to the controller.
Approve the replacements, see Approving

Note
23
5 Approving and reporting the replacements

Approving the replacements
Use this procedure to approve all replacement procedures in this manual.
Action
1
Switch to manual mode.
Verify that the following LEDs on the panel

board are lit.
EN
MS
NS
ES1
ES2
GS1
GS2
Press the emergency stop button on the

teach pendant.
Verify that the LEDs EN1 and EN2 on the
panel board are not lit.
Check the teach pendant for the error
messages 20202 Emergency Stop open
and 10013 Emergency stop state.
Reset the emergency stop and press the

motor on button.
Press the emergency stop button on the

controller.
Verify that the LEDs EN1 and EN2 on the
panel board are not lit.
Check the teach pendant for the error
messages 20202 Emergency Stop open
and 10013 Emergency stop state.
Reset the emergency stop and press the

motor on button.
Jog the manipulator so that all axes are

moved.
Switch to automatic mode.
Verify that the following LEDs on the panel

board are lit.
EN
MS
NS
ES1
ES2
GS1
GS2
AS1
AS2
10 Test the brakes. See Instruction - Brake

testing for manipulators.
Note
If the brakes are not working then inform

the customer. The replacement procedure
can only be approved if the brake test is
successful.

25

Continued
Action
Note
11 If the brake test is successful, fill in the report and upload it in WebConfig, see Uploading the report to WebConfig on
page 26.
Uploading the report to WebConfig

Use this procedure to upload the report of the approved replacements to WebConfig.
Action
Note
Login to ABB Robotics Service Portal and http://roboticsportal.se.abb.com

go to WebConfig.
In the field Serial/Order/Issue type the robot serial number. Click Search.
In the section SYSTEM STRUCTURE, click

on the link for the controller.
In section MODULE DOCUMENTS, click

Upload document.
Click Browse and select your document,

Machine Directive Check List.
Click Upload document to upload the
document to WebConfig.
26
Index
Index
A
revision, 11
approving replacements, 25
safety, 8
DSQC 331, 23
DSQC 504, 19
DSQC 509, 23
E
emergency stop
replacing on controller, 17, 19
replacing on teach pendant, 13
enabling switch
replacing, 14
M
Machine Directive Check List, 26
teach pendant
emergency stop, 13
enabling switch, 14
testing, 25
TPU
emergency stop, 13
enabling switch, 14
U
upload documents, 26
W
WebConfig, 26
panel board, 23
27
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VSTERS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics
Discrete Automation and Motion
Box 265
N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.
5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics
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ABB Robotics

Trace back information:

Copyright 2012-2012 ABB. All rights reserved.

Copyright 2012-2012 ABB. All rights reserved.

About the safety kit

Replacing parts on the teach pendant

Replacing parts on the controller

Approving and reporting the replacements

This page is intentionally left blank

Overview of this instruction

Overview of this instruction

be trained by ABB and have the required knowledge of mechanical and

Instruction - Brake testing for manipulators

Operating manual - Emergency safety information

Be aware of stored electrical energy (DC link) in the controller.

The mains supply/mains switch

The power unit

The drive unit (400/800 VDC)

The service outlets (115/230 VAC)

3HAC045800-001 Revision: Copyright 2012-2012 ABB. All rights reserved.

1 About the safety kit

1 About the safety kit

This page is intentionally left blank

Safety kit with the panel board included

Safety kit without the panel board included

Safety kit with the panel board included

Safety kit without the panel board included

Kits for S4C+

Kits for S4C+ Automotive

Safety kit with the panel board included

Safety kit without the panel board included

This page is intentionally left blank

3 Replacing parts on the teach pendant

3 Replacing parts on the teach pendant

Disconnect the teach pendant and place it

Loosen the screws holding the bottom

Release the contact blocks by pulling the

Loosen the nut inside the teach pendant

Tighten the nut holding the emergency stop

Continues on next page

3 Replacing parts on the teach pendant

Continue with replacing the enabling

Replacing the enabling switch

Disconnect the enabling switch cable from

Loosen the nut and remove the plastic

Remove the cap and release the nut.

Remove the enabling switch and the

Put the new enabling switch harness in

Continues on next page

3HAC045800-001 Revision: Copyright 2012-2012 ABB. All rights reserved.

3 Replacing parts on the teach pendant

Put the plastic bracket back in place and

Put the bottom case back in place. Make

Tighten the screws fully.

Continue with replacing the parts on the

This page is intentionally left blank

4 Replacing parts on the controller

4 Replacing parts on the controller

Open the top cover of the controller and

Remove the auto/manual switch to enable

For each brake and motor on contactor:

Continues on next page

4 Replacing parts on the controller